Vibratory tray conveyor and method

ABSTRACT

A tray for vibratory conveying of food articles from a hopper is provided. The tray includes a tray body, food inlet portion, and a food outlet portion. An upwardly extending dividing member divides the tray into at least two food inlet conveyor passageways, the inlet conveyor passageways merging into a single food passageway that extends to the food outlet portion. The single food passageway may have an initially wide portion and subsequently narrow to a narrow portion as it approaches a discharge end. This arrangement helps to declump food items, preferably causing food items the size of chicken nuggets to be conveyed in a single-file arrangement along the single food passageway. The single food passageway is preferably non-linear, and may, for example, have a zigzag or serpentine configuration to promote accurate dispensing of food items.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 10/419,523,filed on Apr. 21, 2003, pending. Application Ser. No. 10/419,523 is acontinuation-in-part of U.S. application Ser. No. 10/127,202, filed onApr. 22, 2002, pending; Ser. No. 10/127,203, filed on Apr. 22, 2002,granted, now U.S. Pat. No. 6,869,633; Ser. No. 10/127,309, filed on Apr.22, 2002, granted, now U.S. Pat. No. 6,960,157; Ser. No. 10/127,311,filed on Apr. 22, 2002, abandoned; Ser. No. 10/127,369, filed on Apr.22, 2002, pending; Ser. No. 10/127,390, filed on Apr. 22, 2002,abandoned; Ser. No. 10/127,398, filed on Apr. 22, 2002, granted, nowU.S. Pat. No. 6,871,676; and Ser. No. 10/127,400, filed on Apr. 22,2002, the entire disclosure of each of the foregoing applications ishereby expressly incorporated by reference.

FIELD OF THE INVENTION

The invention relates to automated food processing. More particularly,the invention relates to automated food dispensing, frying and packaginginto individual portion-sized containers such as at a quick-service typerestaurant.

BACKGROUND OF THE INVENTION

In restaurants, especially quick-service (fast food) restaurants, fast,consistent, efficient and safe food preparation is essential for asuccessful operation. The quality of the prepared food depends in largepart on the consistency of food preparation. The food must be cookedunder correct conditions for the proper time.

Consistency in food preparation can vary as a result of many factors.For example, people engaged in food preparation often must performmultiple tasks at frequencies that vary with time because of constantlyvarying customer demand throughout the day. For example, lunchtime anddinnertime may be extremely busy while other periods may be relativelyslow. The product mix can vary from hour to hour and day to day. As aresult, the consistency and quality of food may vary. Difficulties inproper scheduling of food production during peak and non-peak periodscan cause customer delays and/or stale, wasted or unusable food.

Food preparation can be labor intensive, and thus, the labor cost can bea large portion of the total cost of the prepared food. An additionalproblem is that in sparsely populated and other areas wherequick-service restaurants are located, such as along interstatehighways, for example, recruiting sufficient numbers of suitableemployees is difficult.

Quick-service restaurants must be able to effectively meet a variablecustomer demand that is time dependent and not subject to preciseprediction. As a result, stores relying totally on human operators willat times be overstaffed and at other times be understaffed. Also,problems and potential problems can exist in restaurants where peopledirectly prepare food. Health and safety concerns can also be presentwhere food is prepared directly by people. By reducing or minimizinghuman contact with food and food cooking equipment, health and safetyconcerns can also be reduced or minimized. For example, in the frying offoods, some type of hot fluid, such as cooking oil or shortening must beutilized. The cooking temperatures required can present a concern forhealth and safety.

Although quick-service restaurants have existed for many years and nownumber in the tens of thousands, such establishments utilize manuallabor to prepare and process food. While there have been variousimprovements in commercial equipment used for cooking food inquick-service restaurants, such restaurants are believed to besubstantially all manually operated and relatively labor intensive.

Accordingly, a need exists for an automated, commercially suitable fooddispensing, cooking and packaging device, system and method for friedfoods that can be operated with a minimum of human intervention, controland maintenance. More particularly, a need exists for an automateddevice, system and method that is capable of, without human labor,frying various food products in desired quantities, such as Frenchfries, seasoning the cooked food and packaging the cooked food inindividual portion-sized containers.

SUMMARY OF THE INVENTION

In accordance with the present invention, an automated food processingsystem and method is provided. The automated food processing system andmethod in accordance with the invention allows food to be dispensed,fried and packaged in a suitable container or alternatively dispensed toa food holding area for subsequent processing by a human operator.

In accordance with one aspect of the present invention, an automatedmodule system for dispensing, frying and packaging food into individualportion-sized containers is provided. In one embodiment, any suitableautomated dispensing device can be used. In another embodiment, thesystem includes an automated dispensing module capable of dispensing adesired quantity of food to be fried, an automated fry module adjacentthe dispensing module to receive and fry the quantity of food dispensedfrom the dispensing module and to produce and dispense a quantity offried food and an automated packaging module adjacent the fry module toreceive and package the fried food from the fry module into anindividual portion-sized container.

Advantageously, in one embodiment, the three modules are independentfrom each other and can be operated independently. Plus, in oneembodiment, any one of the modules can be deactivated and a humanoperator can manually perform the function of the deactivated modulewith manually operated equipment.

In accordance with another aspect of the invention, optionally anautomated seasoning device is present to apply seasoning to the food.

Typically, the automated dispensing module in accordance with theinvention in one embodiment is capable of dispensing one or more ofuncooked or, unheated French fries, chicken nuggets, hash browns,chicken patties and fish filets or similar types of food items to becooked and/or heated.

In accordance with another aspect of the invention, the automateddispensing module includes a freezer, a storage container located in thefreezer for containing food to be dispensed, structure for dispensing apredetermined quantity of food from the storage container into asecondary or dump container, with the structure for dispensing and thesecondary or dump container being located in the freezer, and structurefor dispensing the quantity of food from the secondary or dump containerto a location outside of the freezer.

In accordance with another aspect of the present invention, the frymodule of the automated modular system includes a fry vat for containingand heating cooking oil, at least one circular fry wheel having at leasta generally circular perimeter in a plurality of compartments, eachcompartment having an opening towards the perimeter, the fry wheelmounted for rotational movement relative to the radial axis of the frywheel, which radial axis is disposed above the normal operating level ofthe frying oil or the cooking oil in the fry vat. A drive mechanism isprovided for rotating the fry wheel. In one aspect of the invention, anysuitable type of automated fry device can be utilized.

In accordance with another aspect of the present invention, a controlsystem is provided for causing the drive mechanism to periodicallyrotate the fry wheel back and forth through a relatively small amount ofangular rotation (such as about 2-10°, for example) to simulate shakingof a fry basket. Such control can be accomplished electronically bydevices known to those skilled in the art.

In another embodiment, food is delivered from the fry module to a cookedfood holding device, which can comprise a heated holding bin or bins.

In accordance with still another aspect of the present invention, theautomated packaging module includes a rotatable food dispensing memberhaving an inlet location to receive a quantity of cooked food at adischarge location to discharge cooked food, the packaging module alsoincluding a food dispensing chute positioned to receive cooked food fromthe discharge location of the rotatable food dispenser, the fooddispensing chute having a discharge location.

In accordance with another embodiment of the invention, the automatedmodular system further includes a carton holding device for holding theindividual portion-sized carton or container in position to receive foodfrom the discharge location of the dispensing chute. The packagingmodule may further include a rotatable food collecting member disposedto collect food from the discharge location of a dispensing chute thatis not deposited into the individual portion-sized food container. Theso collected food may be subsequently deposited into the food dispensingchute for delivery to a container or alternatively to the rotatable fooddispensing member or to a waste receptacle or chute.

In accordance with another aspect of the invention, the automatedpackaging device includes a conveyor system for transporting filledindividual portion-sized food containers from adjacent the fillinglocation to a filled food container holding area, for subsequent pick-upby a human operator, for example. In one embodiment, any suitableautomated packaging device can be utilized.

In accordance with another aspect of the present invention, an automatedfood carton-retrieving device is provided for retrieving and graspingindividual portion-sized food containers. The automated retrievingdevice comprises a movable member for selectively grasping and releasingthe food container. In one embodiment, the retrieving device is capableof grasping and releasing an unerected food container on one side andthe device further includes a second device for selectively grasping theunerected food container on the other side with structure for moving theretrieving device and the second device relatively apart when graspingthe sides of the container to erect or partially erect the container.

In another embodiment, an automated urging structure is provided forurging the container bottom upwardly relative to the sides of thecontainer when the sides of the container are moved relatively apart.

In accordance with another aspect of the invention, the automatedmodular system includes an electronic control system that receivescurrent customer order information and the electronic control systemcauses the selection of a container from a plurality of differentcontainer sizes and further causes filling of food with the size of foodcontainer in response to a customer order. In one aspect, the electroniccontrol system can receive customer order information and controls thedispensing rate of food dispensed from the food dispensing module to thefry module which dispensing automatically determines the amount of foodbeing fried without further intervention by the electronic control. Inone aspect, the control system can include a separate control system foreach of the dispensing, fry and packaging systems or modules, each ofwhich interface with a central control system, which in turn optionallyinterfaces with a POS (point-of-sale) system.

In accordance with another aspect of the invention, the automatedmodular system is suitable for dispensing, frying and packaging Frenchfries into individual portion-sized containers.

In accordance with another aspect of the present invention, an automatedmethod of dispensing, frying and packaging food into individualportion-sized containers is provided that includes dispensing a desiredquantity portion of food to be fried from an automated dispensing moduleto an automated fry module and thereafter frying the portion of fooddispensed from the dispensing module in the automated fry moduleadjacent the dispensing module to produce a quantity of fried food.Thereafter, the quantity of fried food is dispensed from the fry moduleto a packaging module where the fried food dispensed from the fry moduleis packaged into individual portion-sized containers with an automatedpackaging module.

In another aspect of the invention, the automated method furthercomprises seasoning the quantity of fried food with a seasoning device.

In accordance with another aspect of the invention, the dispensingincludes dispensing a predetermined quantity of food from the storagecontainer into a secondary container located in a freezer and dispensingthe quantity of food from the secondary container to a location outsideof the freezer.

In accordance with another aspect of the method of the presentinvention, the frying comprises a rotating fry wheel having at least agenerally circular perimeter and a plurality of compartments, eachcompartment having an opening towards the perimeter, the food beingcontained in at least one of the compartments during the frying, the frywheel being mounted for rotational movement relative to the radial axisof the fry wheel in a fry vat with the radial axis being disposed abovea normal operating level of the cooking oil in the fry vat. Inaccordance with this aspect of the invention, the automated methodfurther includes containing a drive mechanism to periodically rotate thefry wheel back and forth through a relatively small amount of angularrotation to simulate shaking of a fry basket during frying.

In accordance with another aspect of the invention, the packagingincludes rotating a rotatable food dispensing member having an inletlocation to receive a quantity of cooked food in a discharge location todischarge cooked food, the food dispensing member being rotated todispense food into a food dispensing chute position to receive cookedfood from the discharge location of the rotatable food dispenser andthereafter dispensing said food from the dispensing chute to a containerto be filled.

In accordance with another aspect of the invention, the method furtherincludes holding an individual portion-sized carton or containerpositioned to receive food from the dispensing chute with an automatedcarton holding device.

In accordance with still another aspect of the invention, the methodfurther includes collecting food dispensed from the discharge locationof the dispensing chute that is not deposited into the individualportion-sized food container with a rotatable food collecting memberdisposed to collect such not deposited food.

In accordance with another aspect of the method, the method includeselectronically coordinating the operation of the three modules ordevices within an electronic control system. In one embodiment, themethod further includes electronically receiving current customer orderinformation by the electronic control system which causes selection of acontainer from a plurality of different sized containers and filling thecontainer with food of the ordered size of food container in response toa customer order by the packaging module. In accordance with anotheraspect of the method, customer order information is electronicallyreceived and the dispensing rate of food dispensed from the fooddispensing module to the fry module is controlled, which dispensingautomatically determines the amount of food being fried without furtherintervention by the electronic control system.

In accordance with another aspect of the present invention, an automateddispensing device for dispensing a quantity of food to be subsequentlycooked is provided. In one embodiment, the automated dispensing deviceincludes a freezer or refrigerated compartment, a storage containerlocated in the freezer for containing food to be dispensed, structurefor dispensing a predetermined quantity of food from the storagecontainer into a secondary or dump container, the structure fordispensing the predetermined quantity of food being located in thefreezer, and structure is provided for dispensing the quantity of foodfrom the secondary or dump container in the freezer to a locationoutside of the freezer.

In one embodiment, the structure for dispensing a predetermined quantityof food includes a vibratory conveyor typically located in the freezerbelow the storage container. The structure for dispensing may furtherinclude a device for determining or sensing the quantity of food thathas been deposited in the secondary container and structure is providedfor terminating the operation of the structure for dispensing when apredetermined quantity of food is sensed in the secondary container.

In accordance with another aspect of the present invention, thesecondary container has a bottom that is at least partially open and thesecondary container is movable laterally between a filling positionlocated within the freezer and a dispensing position for dispensing foodthrough the container open bottom and out of the freezer. The secondarycontainer may include a floor member that is located below the containerhaving the at least partially open bottom. The floor member and thecontainer are movable relative to each other between the first andsecond positions wherein in the first position the floor member isadjacent the open bottom and prevents food from being dispensed from thecontainer and when in the second position food is free to fall throughthe open bottom of the container.

In one embodiment, a device for determining the quantity of food locatedin the second container is provided with structure for terminating theoperation of the structure for dispensing food into the second containerwhen a predetermined quantity of food is sensed in the secondarycontainer. The device for determining the quantity may be on a volume orweight basis and thus can be a weighing mechanism, which can be a loadcell. In one embodiment, a device is provided for moving the secondcontainer laterally sufficiently to the dispensing position so that foodcontained therein is dispensed. Such a device may be, for example, asuitable actuator, which can be an air or hydraulic cylinder, forexample. In one embodiment, the automated dispensing device furtherincludes a door that is located over an opening in the freezercompartment and positioned relative to the secondary container so thatwhen the secondary container is moved laterally to the dispensingposition, the food in the secondary container exits the freezercompartment through the open bottom and through the freezer compartmentopening. Typically, the dispensed food will then be directed into thefry module.

In accordance with another aspect of the present invention, a vibratoryconveyor is provided for conveying food items to the secondarycontainer. The vibratory conveyor in one embodiment may have aserpentine or a zigzag food travel pathway.

In accordance with another aspect of the invention, the tray forvibratory conveying of food articles from a hopper may include a traybody, a food inlet portion and a food outlet portion, the food inletincluding an upwardly extending dividing member for dividing the trayinto at least two food inlet conveyor passageways, the inlet conveyorpassageways merging into a single food passageway that extends to thefood outlet portion after which the food passing therethrough isdispensed into the secondary container. In one embodiment, the singlefood passageway may be nonlinear and may have a zigzag or a serpentinepathway or configuration. In one aspect of the invention, the dividingmember of the tray for vibratory conveying of food articles issaddle-shaped. The tray for vibratory conveyance of food articles can beconfigured and dimensioned so that the single food passageway causesfood of a particular size, such as the size of chicken nuggets, forexample, to be conveyed in a single file arrangement. This allows for aprecise vibratory dispensing of the food articles permitting them to bedispensed one at a time from the vibratory conveyor to the secondarycontainer. Such an arrangement permits accurate metering of the foodarticles and precise control of the batch sizes that are cooked andsubsequently packaged and served to customers. This permits moreeconomical and efficient and reproducible operations.

In accordance with another aspect of the present invention, thevibratory conveyor includes a tray that has a bottom portion with aplurality of spaced apart holes to permit relatively small undesirableparticles, such as ice particles and small particles of food to passtherethrough so that such material is not dispensed into the secondarycontainer. To accomplish this, typically the holes will be less thanabout 0.25 inches in diameter and can be located in a suitable array asdesired.

In accordance with another aspect of the invention, a generallyvertically extending declumping member is provided that can interactwith food contained in the vibrating conveyor. Preferably, thedeclumping member is in the form of a cylindrical member or pin thatextends generally vertically towards the vibrating conveyor from aposition located above the vibrating conveyor. Typically, the declumpingmember will be stationary relative to the vibrating conveyor so that asfood, in particular, such as French fries, pass the declumping member asthey travel along the vibrating conveyor clumps of French fries can beseparated into smaller clumps or individual French fries. Thisfacilitates the subsequent frying of such food materials.

In accordance with another aspect of the present invention, theautomated dispensing device includes structure for dispensing apredetermined quantity of food that comprises a food magazine capable ofdispensing individual pieces of food on a piece by piece basis. Inaccordance with a more specific aspect of this embodiment, the magazinecomprises dual rotatable spiral flights with the spiral flights having aspacing therebetween to allow placement of a food item, such as achicken patty, for example, to be supported by both spiral flights.

In accordance with another aspect of the invention, the magazinedispenser is suspended from a slide mechanism permitting removal of themagazine from the freezer or refrigerated compartment. A plurality ofthe magazines can be located on a single slide mechanism. An array ofthe magazines may be located in the freezer, such as a 3×5 array or a3×4 array, for example.

In one embodiment, a separate drive motor is associated with each fooddispensing magazine for selectively rotating spiral flights of amagazine dispenser for dispensing a desired number of the food items.The drive motor may also be located in the freezer.

In accordance with another aspect of the invention, an automated methodof dispensing a quantity of food to be cooked is provided. The methodincludes storing food items in a storage container located in thefreezer, dispensing food items from the storage container to a conveyor,conveying the food items on the conveyor to a secondary or dumpcontainer located in the freezer, monitoring the amount of food itemsdelivered to the secondary container, terminating delivery of the fooditems to the secondary container when a desired amount of food items aredetermined to be present in the secondary container as determined by themonitoring, and dispensing the food items from the secondary containerand out of the freezer by at least partially inverting the secondarycontainer. In accordance with another aspect of this embodiment, afreezer or refrigerated compartment is not utilized.

In accordance with another aspect of the present invention, the methodincludes storing food items in a storage container, dispensing fooditems from the storage container to a conveyor, conveying the food itemson the conveyor to a secondary container having at least a partiallyopen bottom with a floor member adjacent the open bottom, monitoring theamount of food items delivered to the secondary container, terminatingdelivery of the food items to the secondary container when a desiredamount of food items are determined to be present in the secondarycontainer as determined by said monitoring and dispensing the food itemsfrom the secondary container and through the open bottom of thesecondary container by relative movement of the floor member to the openbottom of the container.

The conveying may comprise vibratory conveying, as desired.

In one embodiment, the secondary container with the at least partiallyopen bottom moves relative to the floor member that remains stationary.

In accordance with another aspect of the present invention, a device forthe automated frying of foods is provided. The device in one embodimentincludes a fry vat for containing and heating cooking oil, at least onecircular fry wheel having at least a generally circular perimeter and aplurality of compartments with each compartment having an openingtowards the perimeter, the fry wheel mounted for rotational movementrelative to the radial axis of the fry wheel which radial axis isdisposed above the normal operating level of the frying oil in the fryvat. A drive mechanism is provided for rotating the fry wheel and acontrol system is included for causing the drive mechanism toperiodically rotate the fry wheel back and forth through a relativelysmall amount of rotation (such as about 2-10°, for example) to simulateshaking of a fry basket. Such control can be accomplished electronicallyby devices known to those skilled in the art.

In accordance with another aspect of the present invention, the smallamount of rotation is in the range of from about 2° to about 20°. Theback and forth rotation in one direction may be of a larger angle oramount of rotation than of the rotation in the other direction.

In one embodiment, a control system is provided that causes periodicincremental rotation of the fry wheel in one direction to cause fooddeposited into one of the compartments to travel through the cooking oilin the fry vat over a period of time to fry the food and to move thecompartments out of the cooking oil for subsequent discharge of the foodfrom the compartment. In one embodiment, the periodic incrementalrotation is based on 360° divided by the number of compartments in thefry wheel.

In accordance with another aspect of the present invention, a controlsystem is provided for operating the drive mechanism to rotate the frywheel in one direction to cause food deposited into one of thecompartments to travel through the cooking oil in the fry vat over aperiod of time to fry the food and out of the cooking oil for subsequentdischarge of the food from the compartment, wherein the control systemadjusts the speed of rotation based on the level of cooking oil in thefry vat. In one embodiment, the control system causes incrementalperiodic rotation of the fry wheel and the control system adjusts theperiod of time between incremental rotations based on the level ofcooking oil sensed in the fry vat. The period of time betweenincremental rotations can also be based on the temperature of thecooking oil in the fry vat.

In accordance with another aspect of the invention, a curved baffle isprovided that is disposed in the fry vat adjacent the axial periphery ofthe portion of the fry wheel that is disposed in the cooking oil forpreventing food contained in one or more of the fry wheel compartmentsfrom falling out of the compartments.

In accordance with another aspect of the invention, a device for theautomated frying of food is provided that includes a fry vat forcontaining and heating cooking oil, at least one circular fry wheelhaving at least a generally circular perimeter and a plurality ofcompartments each having an opening towards the perimeter, the fry wheelmounted for rotational movement relative to the radial axis of the wheelwhich radial axis is disposed above the normal operating level of thefrying oil in the fry vat, a drive mechanism for rotating the fry wheeland an overflow passageway having an inlet that is located above thenormal operating level of the frying oil in the fry vat. Preferably, theoverflow passageway is located in a foam deck that is adjacent a side ofthe fry vat. The foam deck has a surface located above the normaloperating level of the frying oil in the fry vat. In one embodiment, theoverflow passageway comprises an elongated slot in the foam deck. Thefoam deck is preferably located adjacent or in proximity to the foodinlet location for supplying a quantity of food to be fried in the frywheel.

In accordance with another aspect of the present invention, an automatedmethod of frying food in a fry vat having a heated cooking oil containedtherein is provided. The method includes placing food in a fry wheelcompartment, each of the compartments having an opening towards theperimeter of the fry wheel, rotating the fry wheel so that thecompartment containing the food travels submerged in the heated cookingoil and periodically rotating the fry wheel back and forth in arelatively small amount of rotation to simulate shaking of the frybasket while the food is submerged in the cooking oil. In accordancewith another aspect of the method of the present invention, the methodcomprises rotating the fry wheel in one direction to cause the fooddeposited into one of the compartments to travel through the cooking oilin the fry vat over a period of time to fry the food and to move thefood out of the cooking oil for subsequent discharge of the food fromthe compartment, wherein the speed of said rotating is related to thelevel of cooking oil in the fry vat. In accordance with this aspect ofthe present invention, the rotating may comprise incremental periodicrotation with the period of time between incremental periodic rotationsbeing based on the level of cooking oil sensed in the fry vat. Theperiod of time between incremental periodic rotations may also be basedon the temperature of the cooking oil in the fry vat.

In accordance with another aspect of the invention, an automated methodof frying food is provided that includes placing food to be fried in afry wheel compartment of a fry wheel having at least a generallycircular perimeter and a plurality of compartments, each having anopening towards the perimeter, the fry wheel mounted for rotationalmovement relative to the radial axis of the wheel which radial axis isdisposed above the normal operating level of the frying oil in a fry vathaving heated cooking oil therein, providing an overflow passagewayhaving an inlet that is located above the normal operating level of thefrying oil in the fry vat, collecting in the overflow passageway atleast some of the water containing foam that results when food to befried and placed in the fry wheel contacts the frying oil and rotatingthe fry wheel so that the compartment containing the food travelssubmerged in the heated cooking oil. The method may further includeperiodically rotating the fry wheel back and forth with a relativelysmall amount of rotation to simulate shaking of a fry basket while foodis submerged in the cooking oil.

In accordance with another aspect of the present invention, an automatedmethod of packaging cooked food, which may be food such as French fries,chicken nuggets and other types of food, in an individual portion-sizedcontainer is provided. The method includes delivering a quantity of acooked food to a rotatable dispensing member, rotating the dispensingmember to cause the food items to fall from one or more compartments ofthe dispensing member into a food dispensing chute and thereafterdispensing the food from the chute and depositing the food into theindividual portion-sized food container.

In accordance with one aspect, the method may further include weighingthe food in the chute before dispensing the food to the container.

In accordance with another aspect of the invention, the method includesapplying seasoning to the food and may further include applying theseasoning by using gravity to cause the seasoning to travel through anozzle and onto the food.

In accordance with another aspect of the invention, the method furtherincludes shaking the individual portion-sized food container after thedispensing. The shaking may be automated and can include back and forthmovement of the container through an arc as desired, and may be in agenerally vertical axis. The arc may be a generally circular arc and therotating back and forth may encompass an arc in the range of from about3° to about 20°. In addition, the container may be raised and loweredbefore, during or after the rotating to further simulate shaking or inconnection with further container handling.

In accordance with another aspect of the invention, when dispensing foodfrom the chute to the individual portion-sized container, some of thedispensed food is not deposited into the individual portion-sizedcontainer and the method further includes collecting the not depositedfood. Typically, the not deposited food will be collected in acollection device that returns the not deposited food to the chute forsubsequent dispensing. In one embodiment, the collection member isrotatable and can be rotated to deposit the collected food to the chute.This helps to ensure that the not deposited food is subsequentlydeposited into a container on a first-in, first-out or a generallyfirst-in, first-out basis.

In accordance with another aspect of the present invention, an automatedmethod of packaging food, including food such as French fries, in anindividual portion-sized container is provided that includes deliveringa quantity of food to a food dispensing chute, selecting and holdingwith an automated device an individual portion-sized container of adesired size from a plurality of different sizes of individualportion-sized containers that can be selected and held by the automateddevice. The selected individual portion-sized container is moved by theautomated device to a location for receiving food from the dispensingchute and food is dispensed from the chute and into the container. Themethod may further include depositing the filled food container onto aconveyor by operation of the automated device and transporting thedeposited container by the conveyor to a human operator food pickuplocation.

In accordance with another aspect of the foregoing method, theindividual portion-sized food container is unerected and the methodfurther includes after the selecting, erecting the selected individualportion-sized food container by the automated device. In one embodiment,the automated device includes a partial vacuum suction device forholding the individual portion-sized food container and the holdingincludes applying a partial vacuum through a suction device to the foodcontainer. The food container can be released by reducing or eliminatingthe vacuum applied by the suction device to the food containersufficiently to cause the food container to be disengaged from theautomated device.

In accordance with another embodiment of the method, the filled foodcontainer is placed in an upright position on a transportable member orcontainer-receiving receptacle which in one embodiment contains a singlefood container and is maintained in an upright position on thetransportable member by cooperation of the recessed volume of thetransportable member and the food container.

In accordance with another aspect of the invention, the transporting isperformed by a magnetic conveyor.

In accordance with another aspect of the invention, an automated methodof packaging cooked French fries in individual portion-sized French frycontainers is provided. The method includes delivering with a mechanicaldevice cooked French fries to a French fry holding bin and mechanicallyscooping with a mechanical device an open French fry container into thecooked French fries in the holding bin to fill the French fry containerwith French fries. After filling the French fry container, the methodfurther includes mechanically depositing the filled French fry containerat a drop-off location. Typically, the drop-off location will include alocation that is convenient for a human operator to access the filledFrench fry containers for subsequent service to a customer.

In accordance with this aspect of the invention, typically thedelivering of cooked French fries to a French fry holding bin will beaccomplished by receiving the French fries from an inlet chute whichchute is traversed by the French fries prior to entering the French fryholding bin. When used with a fry module in accordance with theinvention or some other type of fry apparatus including a manual fryoperation, the French fries enter the inlet chute after being dispensedfrom the fry module or other arrangement.

The automated method of packaging cooked French fries may furtherinclude applying seasoning to the French fries which may occur while onthe inlet chute. The application of seasoning is preferably done by anautomated system which may include a seasoning device or a saltingdevice as hereafter described in detail.

In accordance with another aspect of the invention, the inlet chuteincludes structure for vibrating the inlet chute to facilitate transportof French fries down the inlet chute.

In one embodiment, the inlet chute includes a first gate that is movableto a position that restrains the French fries from traveling down thechute. This provides a convenient time during which to apply the desiredseasoning to the French fries. The gate may include a plurality ofreciprocable fingers that are configured for up and down movement. Thefingers may be configured such that in a retracted position the fingersdo not extend above the surface of the inlet chute and in an extendedposition the fingers extend outwardly above the surface of the inletchute sufficiently to prevent the passage of French fries. In addition,in one embodiment, the fingers are periodically reciprocable in an upand down direction so that the fingers have a declumping action onFrench fries passing through the chute at the location of thereciprocable fingers.

In accordance with another embodiment of the invention, the methodincludes further restraining the French fries from exiting the inletchute at a location downstream of the gate after passing the first gate.The further restraining can be performed by a second gate locateddownstream of the first gate. Preferably, when utilized, the second gatewill be located downstream of the first gate a sufficient distance sothat a desired quantity of French fries can be stored on the chutebetween the first and second gates. The second gate can be moved to aposition that does not restrain the French fries so that the Frenchfries are free to travel into the holding bin.

In accordance with another aspect of the automated method of packagingcooked French fries, the method further includes mechanically shakingthe filled individual portion-sized French fry container prior to thedepositing. The shaking may include back and forth movement through anarc in which the end-of-arm tool of the mechanical device travels,thereby causing the filled individual portion-sized French fry containerto travel in that arc which can be any generally vertical axis. Inaccordance with one embodiment, the mechanical device is a mechanicalarm which can perform the mechanical scooping, shaking and depositingsteps as desired. In addition, the method may further include holdingthe individual portion-sized French fry container with a mechanical armof the mechanical device while performing the scooping, shaking and/ordepositing. The shaking may be accomplished by up and down verticalmovement of the mechanical arm.

In accordance with another aspect of the invention, the method furtherincludes mechanically obtaining an unerected individual portion-sizedFrench fry container to be filled from a stack of unerected individualportion-sized French fry containers. The method can still furtherinclude mechanically erecting the unerected individual portion-sizedFrench fry container prior to the scooping. The method may furtherinclude, before the obtaining of the unerected carton, selecting andholding with the mechanical device an individual portion-sized containerof a desired size from a plurality of different sizes of individualportion-sized containers that can be selected and held by the automateddevice.

In accordance with another aspect of the present invention, a method oferecting a collapsed, individual portion-sized French fry container ofthe type having opposed sidewalls connected by a collapsible containerbottom is provided. The method includes grasping the unerected Frenchfry container, pulling the container against a restraining member andmechanically dragging the bottom of the container so that it traversesup an inclined ramp to urge up the container bottom to urge thecontainer to an erected position. The method may further includeinjecting a stream of compressed air into the open end of the containerand towards the container bottom for assisting in the erecting.

As used herein, the term “fill” or “filled” is not limited to completelyfilling or a completely filled container and thus includes partiallyfilling or partially filled containers.

In accordance with still another aspect of the invention, an automateddevice for packaging cooked food into a desired container, which may bean individual portion-sized food container is provided. The deviceincludes a rotatable food dispensing member having an inlet location toreceive a quantity of the cooked food and a discharge location todischarge the cooked food. A food dispensing chute is positioned toreceive the cooked food from the discharge location of the rotatablefood dispenser and the dispensing chute has a discharge location. In oneembodiment, the dispensing chute has a food holding area for holding aquantity of the cooked food deposited therein. A suitable weighingdevice can be associated with the dispensing chute to weigh the foodthat is contained in the chute or in the holding area of the chute. Inone embodiment, the weighing device is a load cell.

In accordance with another aspect of the invention, the automated deviceincludes a food carton or container holding device for holding the foodcarton in position to receive food from the discharge location of thedispensing chute. The carton holding device can include an axiallyrotatable generally vertically extending elongated first member and asecond member that extends from the elongated member, the second memberhaving a gripping member for gripping a food container, which may be anindividual portion-sized food container. In one embodiment, the grippingmember comprises a suction cup. A vacuum source may be supplied to thesuction cup to create at least a partial vacuum, allowing the containerto be held. In one embodiment, the carton holding device is capable ofmoving the food container through an arc of about or of at least about180° and in which the carton holding device is capable of moving thefood container up and down.

In accordance with another aspect of the present invention, theautomated device comprises a conveyor system for transporting filledindividual portion-sized food containers from adjacent the fillinglocation to a filled container holding area. The conveyor system maycomprise in one embodiment a continuous loop raceway and a plurality ofdiscrete movable food container receptacles that are movable along theraceway. The conveyor system may include a continuous movable loophaving at least one magnetic element capable of magnetically attractingone of the movable receptacles at a time for causing movement of thereceptacle corresponding to movement of the magnetic element. Aplurality of the magnetic elements may be spaced apart along the movableloop.

In one embodiment, structure is provided for preventing movement of thediscrete receptacles when the structure for moving the discretereceptacles along the raceway is activated. The structure for preventingmovement can be a barrier that is disposed across the raceway. In oneembodiment, the barrier is selectively movable and in another embodimentthe barrier is fixed. In one embodiment, the barrier prevents movementof the receptacles only for a receptacle that has a food carton orcontainer disposed thereon. In this embodiment, the barrier may belocated at a height that is above the top of the receptacles located onthe conveyor system adjacent the barrier.

In accordance with another aspect of the invention, an automated deviceis provided to retrieve and grasp a food container, which may be anindividual portion-sized food or French fry container or carton. Theautomated retrieving device includes a member for selectively graspingand releasing the food container and for moving the movable memberhorizontally and linearly.

In accordance with another aspect of the invention, a magazine isprovided for holding a plurality of food containers in an unerectedstate.

In accordance with another aspect of the invention, the automated deviceincludes a retrieving device that is capable of grasping and releasingan unerected food container on one side and further includes a seconddevice for selectively grasping the unerected food container on theother side. A structure for moving the retrieving device and the seconddevice relatively apart when grasping the sides of the container isprovided. The automated device may further include an automated urgingmeans for urging the container bottom upwardly relative to the sides ofthe container when the retrieving device and the second device are movedrelatively apart when grasping the container.

In accordance with another aspect of the invention, the food dispensingmember is a rotatable wheel having an open central area and an outer atleast generally circular rim. The rotatable wheel has a plurality ofopen compartments spaced apart about the circular rim that extendinwardly from the circular rim and open interiorly of the circular rim.A baffle may be provided to prevent food contained in the one or more ofthe open compartments from falling out of the compartments when thewheel is rotated until the compartment is in position over the fooddispensing chute. The baffle may be curved to follow the curvature ofthe inner part of the wheel and may also be perforated. The automateddevice may further include a rotatable food collecting member that isdisposed to collect food dispensed from the discharge location of thedispensing chute which food is not deposited into a container held inposition at the discharge location. Typically, the collection memberwill have a discharge location to discharge collected food. In oneembodiment, the discharge location is the food dispensing chute. Thecollecting member may be a rotatable food collecting wheel having anopen central area and an outer circular rim having a plurality of opencompartments spaced apart about the circular rim that extend inwardlyfrom the circular rim and that are open towards the rim interior. Therotatable food dispensing member and the rotatable food collectingmember can be rotatable in one direction to discharge food at adischarge location and into a food dispensing chute and can be rotatablein an opposite direction to discharge the food at a second dischargelocation which may be to a waste chute. The discharge to the waste chutefeature can be activated, for example, when the food is held in thedispensing device for too long a period of time.

The packaging device may also include an automated seasoning device fordepositing a predetermined quantity of seasoning to food contained inthe packaging device.

In accordance with another aspect of the invention, the device forapplying seasoning includes a seasoning delivery tube having an inletand a discharge location. A seasoning delivery head is positioned todeliver seasoning to the food to be seasoned with the head incommunication with the outlet of the delivery tube and located below theinlet of the delivery tube. Structure is provided for depositing apredetermined quantity of seasoning into the inlet of the delivery tubeso that the quantity of seasoning falls by gravity through the deliverytube and into and through the seasoning head and onto the food to beseasoned. Typically, the structure for depositing the predeterminedquantity of seasoning will receive seasoning from a bulk hopper bygravity feed. The quantity of seasoning to be dispensed can bedetermined volumetrically, for example.

In accordance with still another aspect of the invention, an automateddevice for packaging cooked French fries into an individualportion-sized French fry container is provided. The device includes amechanical arm having an end-of-arm tool capable of picking up andgrasping an erected individual portion-sized French fry carton from anerected carton pick-up location, and scooping the erected carton whileheld by the end-of-arm tool into a quantity of cooked French frieslocated at a filling location to fill the French fry carton andthereafter depositing the filled French fry carton at a drop-offlocation spaced from the filling location. The automated device mayfurther include a French fry holding bin for holding a bulk quantity ofFrench fries at the filling location and a French fry inlet chute forreceiving a bulk amount of French fries. In one embodiment, theautomated device further includes structure for vibrating the French fryinlet chute. In accordance with another aspect of the invention, theautomated device further includes structure for retaining French frieson the French fry chute and may further include structure for applyingseasoning to the French fries contained on the inlet chute.

In accordance with another aspect of the invention, the structure forretaining French fries on the chute is composed of a plurality ofvertically reciprocable fingers movable between an extended position forretaining French fries on the inlet chute and a retracted position forpermitting French fries to travel on at least a portion of the chute. Inone aspect, the movable gate may comprise a plurality of spaced apartfingers reciprocable in up and down directions to restrain French friesfrom sliding down the inlet chute when in an up position and fordeclumping French fries when the fingers are reciprocated up and downwhen French fries are traveling past the reciprocating fingers.

In accordance with another aspect of the invention, the automatedpackaging device may include a movable gate located between thedischarge end of the inlet chute and the holding bin and movable betweena raised position for retaining French fries on the inlet chute and alowered position for permitting French fries to travel from the inletchute to the holding bin.

In accordance with another aspect of the invention, the French fryholding bin may have a sensing device associated therewith fordetermining whether a desired quantity of French fries are contained inthe French fry holding bin. The sensing device can be any suitabledevice that may be known in the art, such as a weighing device and canbe a load cell, for example.

In accordance with still another aspect of the invention, a French frycarton storage and erection device is provided that includes anautomated, unerected French fry carton retrieving device for retrievingand grasping an unerected individual portion-sized French fry container.The automated retrieving device includes a grasping member forselectively grasping and releasing a French fry container. The automatedretrieving device may further include structure for linearly moving themovable member in two dimensions. The two dimensions may be generallyhorizontal dimensions and may be composed of one or more carriages, onefor each of the dimensions.

In accordance with another aspect of the invention, a magazine forholding a plurality of individual portion-sized French fry containers inan unerected state is provided. In one embodiment, the magazine iscapable of holding a plurality of segregated groups of individualportion-sized unerected French fry containers, each group in theplurality being of a different size container. In one embodiment, themagazine holds each group of unerected containers in a stack, which maybe in either a generally horizontal or a vertical stack. The containerretrieving device can be positionable to retrieve containers from thefront of each stack.

In accordance with another aspect of the invention, the grasping membercomprises a suction device for selectively grasping and releasing aFrench fry container. The suction device may comprise a suction cuplocated on the grasping member that is capable of grasping and releasingthe French fry container by applying and releasing a vacuum,respectively, that communicates with the interior of the suction cup.

In accordance with another aspect of the invention, the retrievingdevice is capable of grasping and releasing a French fry container onone side thereof and the automated erecting device further includesstructure for erecting an unerected French fry container of the typehaving opposed sidewalls connected by a collapsible container bottom.The automated device for erecting the container includes structure forurging the container from an unerected to an erected position and forurging the container bottom upwardly relative to the sides of thecontainer which will occur typically when the retrieving device graspsthe container and retrieves the container from the stack of containers.In one embodiment, the structure for urging comprises an inclined rampwhile in another embodiment, the structure for urging includes anautomated retrieving and container grasping device for grasping one ofthe opposed sidewalls of the unerected container and a restrainingmember for restraining from relative movement the other of the opposedsidewalls when the one sidewall is grasped by the grasping device andmoved in a desired direction. In addition, structure may be provided forinjecting a stream of compressed air into the open end of the containerwhen the opposed sidewalls are at least partially moved apart from eachother to help urge the opposed sidewalls apart to erect the container.

In accordance with another aspect of the present invention, theautomated device further includes an elevator for moving an erectedFrench fry container from a first location proximate the unerectedcontainer retrieving device to a second location. The elevator maycomprise a rodless cylinder configured to carry a receptacle or othersuitable structure for holding an erected French fry container with thereceptacle being movable between first and second locations by therodless cylinder. In one embodiment, the second location is proximatethe mechanical arm so that a French fry container in the second positioncan be grasped by the end-of-arm tool.

In another embodiment of the invention, the mechanical arm of thepackaging module is mounted to a carriage for providing lateral movementof the mechanical arm. The mechanical arm can be configured so that itcan move the end-of-arm tool through a generally vertical compound arcas well as for selectively moving the end-of-arm tool linearly up anddown. In one embodiment, the end-of-arm tool comprises a French fryscoop and further includes a gripping mechanism actuable betweenclamping and non-clamping positions wherein the gripping mechanism cangrasp a French fry container when in the clamping position and releasethe previously grasped French fry container when the gripping mechanismis in the non-clamping position. The gripping mechanism can be capableof grasping one of the opposed sidewalls of an erected French frycontainer. In one embodiment, the gripping mechanism includes afinger-type structure with an actuator device for moving the fingerstructure between the clamping and non-clamping positions. The grippingmechanism can be configured to clamp an upper end of an erected Frenchfry container between the finger structure of the gripping mechanism andthe French fry scoop of the end-of-arm tool.

In another embodiment of the invention, the mechanical arm of thepackaging module includes a plurality of pivotable links connected inseries. In one embodiment, the mechanical arm includes at least twopivotable links and in another embodiment the mechanical arm includesthree pivotable links. The mechanical arm can be configured so that eachof the links is pivotable in the same or in parallel planes. In oneembodiment, the mechanical arm is mounted to a carriage or othersuitable structure for providing lateral movement of the mechanical arm.Typically, the lateral movement will be in a generally horizontaldirection.

In accordance with another embodiment, the mechanical arm includesfirst, second and third links wherein the first link is connected to agenerally horizontally movable carriage, the third link is connected tothe end-of-arm tool and the second link is connected to the first andthird links. A connection of one of each of the links to another linkmay comprise a pivot connection and an actuator may be provided for eachpivot connection for pivoting the respective one of said links about thepivot connection which connects that link to another of the links tocause selective rotation of one link with respect to another of saidlinks.

In accordance with another embodiment of the invention, the automateddevice further includes a structure for containing a plurality of Frenchfry cartons that are filled with French fries, the structure having atleast a portion that is in communication with the drop-off location ofthe mechanical arm. In one embodiment, the structure is a rack that canbe constructed of any suitable material and configuration. In oneembodiment, the rack is inclined in a direction away from the mechanicalarm so that when the mechanical arm drops off a container filled withFrench fries, the container slides down the rack to a convenientlocation for pick-up by a human operator. In another embodiment, thestructure comprises a rotatable carousel. In accordance with anotheraspect of the invention, the mechanical arm is configured to mimic themotion of a person's arm, wrist and hand action in scooping French friesinto a French fry container while grasping the French fry container inone hand and moving the French fry container in a vertical arc andscooping the open end of the French fry container through a quantity ofFrench fries and thereafter moving the French fry container to agenerally upright position and shaking it sufficiently to cause looselycontained French fries to fall from the container. Typically, thisaction occurs with a French fry scoop attached to an upper end of theopen French fry container as is commonly known in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an automated food processing system inaccordance with the invention;

FIG. 2 is a perspective view of an alternate embodiment of a foodprocessing system in accordance with the present invention;

FIG. 3 is a schematic view, partly in section, of the food processingsystem of FIG. 1;

FIG. 4 is a side elevation view of a portion of a bulk food dispensingdevice in accordance with the present invention;

FIG. 4A is a side elevation view, partly in section, of an alternativeembodiment for a portion of the dispensing device illustrated in FIG. 4;

FIG. 5 is a top plan view of a portion of the bulk food dispensingdevice in accordance with the present invention;

FIG. 6 is a side elevation view, partly in section, of a bulk fooddispensing device in accordance with the present invention and alsoillustrating a portion of a device for frying food in accordance withthe present invention;

FIG. 7 is a perspective view of a magazine-type dispenser that can formpart of the food dispensing device of the present invention;

FIG. 8 is a partial side elevation view of the magazine dispenser ofFIG. 7;

FIG. 9 is a perspective view of a magazine-type dispenser array that canbe utilized in the dispenser of the present invention;

FIG. 10 is a fragmentary view of the device of FIG. 9;

FIG. 11 is a top plan view of a food frying device in accordance withthe present invention;

FIG. 12 is a front elevation view of the food frying device of FIG. 11;

FIG. 13 is a partial fragmentary sectional view along line 13-13 of FIG.11;

FIG. 14 is a fragmentary sectional view of a portion of the food fryingdevice of FIG. 11;

FIG. 15 is a sectional view along line 15-15 of FIG. 14;

FIG. 16 is a perspective view of a drive mechanism for the food fryingdevice of FIG. 11;

FIG. 17 is a fry basket for use in the frying device of FIG. 11;

FIG. 18 is a fragmentary sectional view along line 18-18 of FIG. 17;

FIG. 19 is an enlarged, fragmentary elevation sectional view of aportion of FIG. 13;

FIG. 20 is an alternate view along line 13-13 of FIG. 11;

FIG. 21 is a sectional view along line 21-21 of FIG. 20;

FIG. 22 is an enlarged fragmentary view of a portion of FIG. 21;

FIG. 23 is an alternate embodiment of a fry wheel in accordance with thepresent invention;

FIG. 24 is another alternate embodiment of a fry wheel in accordancewith the present invention;

FIG. 25 is a front perspective view of a packaging device in accordancewith the invention;

FIG. 26 is a rear perspective view of the device of FIG. 25;

FIG. 27 is a top plan view of the device of FIG. 25;

FIG. 28 is a side elevation view, partially in section and partiallybroken away of the packaging device of FIG. 25;

FIG. 29 is a side elevation view of the device of FIG. 25;

FIG. 30 is a front perspective view of a portion of an automatedcontainer handling system in accordance with the invention;

FIG. 31 is a top plan view of the container handling system of FIG. 30;

FIG. 32 is a side elevation view, partially broken away of the automatedcontainer handling system of FIG. 30;

FIG. 33 is a rear elevation view of the container handling system ofFIG. 30;

FIG. 34 is a front perspective view of the container handling system ofFIG. 30 shown in another operative position;

FIG. 35 is a top plan view of the container handling system of FIG. 34;

FIG. 36 is a side elevation view, partially broken away of the containerhandling system of FIG. 34;

FIG. 37 is a rear elevation view of the container handling system ofFIG. 34;

FIG. 38 is a front elevation view of a portion of a container handlingapparatus in accordance with the invention;

FIG. 39 is a top plan view of another portion of the container handlingapparatus of FIG. 34;

FIGS. 40-42 illustrate a front diagrammatic elevation view illustratinga portion of the container handling apparatus in accordance with theinvention;

FIGS. 43-44 illustrate a side elevation view, partly in section, of aportion of the food packaging apparatus in accordance with theinvention;

FIG. 45 is a top plan view of a food packaging device in accordance withthe present invention;

FIG. 46 is a perspective view of a container-receiving receptacle inaccordance with the present invention;

FIG. 47 is a top plan view of the device of FIG. 46;

FIG. 48 is a sectional view along line 48-48 of FIG. 47;

FIG. 49 is a cross-sectional view along line 49-49 of FIG. 47 andfurther including a portion of a conveyor system in accordance with thepresent invention;

FIG. 50 is a sectional view along line 50-50 of FIG. 49;

FIG. 51 is a front elevation view of a carton useful in accordance withthe present invention;

FIG. 52 is a rear elevation view of a carton useful in accordance withthe present invention;

FIG. 53 is a sectional view along line 53-53 of FIG. 52;

FIG. 54 is a bottom plan view of the container of FIG. 51;

FIG. 55 is a sectional view along line 55-55 of FIG. 57;

FIG. 56 is a perspective view showing use of the food container of FIG.51;

FIG. 57 is a perspective view of a food container useful in accordancewith the present invention;

FIG. 58 is an alternate embodiment perspective view of a containeruseful in accordance with the invention;

FIG. 59 is a development view of the carton of FIG. 51;

FIG. 60 is a side elevation view of the carton of FIG. 51;

FIG. 61 is a sectional view of a portion of the food packaging device ofFIG. 25;

FIG. 62 is a sectional view of a portion of a food storage device inaccordance with the present invention;

FIG. 63 is a sectional view of the food storage device of FIG. 62;

FIG. 64 is a side elevation view, partly in section, of a hood system inaccordance with the present invention;

FIG. 65 is a perspective view of an automated seasoning device inaccordance with one aspect of the invention;

FIG. 66 is a side elevation view of the seasoning device of FIG. 65;

FIG. 67 is a front elevation view of the seasoning device of FIG. 65;

FIG. 68 is a top plan view of the seasoning device of FIG. 65;

FIG. 69 is a diagrammatic view of a control system in accordance withthe present invention;

FIG. 70 is a diagrammatic view of a control system in accordance withthe present invention;

FIG. 71 is a diagrammatic view of a frying cycle in accordance with thepresent invention;

FIG. 72 is a schematic illustration of a sample touch screen monitoruseful in accordance with the invention;

FIG. 73 depicts another touch screen layout in accordance with thepresent invention;

FIG. 74 is a perspective view of another automated food processingsystem in accordance with the invention;

FIG. 75 is a perspective view of another embodiment of a food processingsystem in accordance with the present invention;

FIG. 76 is a schematic view, partly in section, of the food processingsystem of FIG. 74;

FIG. 77 is a side elevation view of a portion of a bulk dispensingdevice in accordance with the present invention, partly in section;

FIGS. 77A and 77B are perspective views of an alternative embodiment ofa bulk dispensing device in accordance with the present invention;

FIGS. 77C and 77D are perspective and side elevation fragmentary views,partly in section, of an alternate food dispensing device in accordancewith the present invention;

FIG. 78 is a side perspective view of a portion of a bulk dispensingdevice in accordance with the present invention, partly in section;

FIG. 79 is a partial fragmentary perspective view of a conveyor body inaccordance with the present invention;

FIG. 80 is a top plan view of the conveyor body of FIG. 79;

FIG. 81 is a perspective view of a portion of the food dispensing deviceof FIG. 74;

FIG. 82 is a fragmentary perspective view of a portion of the doorassembly illustrated in FIG. 81;

FIG. 83 is a fragmentary perspective view of a portion of one embodimentof a food dispensing device in accordance with the present invention,partly in section;

FIG. 84 is a fragmentary perspective view of a portion of anotherembodiment of a food dispensing device in accordance with the presentinvention, partly in section;

FIG. 85 is a fragmentary perspective view, partly in section, of a frymodule in accordance with one embodiment of the present invention;

FIG. 86 is a fragmentary perspective view illustrating a portion of apackaging module in accordance with the present invention;

FIG. 87 is a front elevation view of various portions of a foodpackaging device in accordance with the present invention;

FIG. 88 is a fragmentary perspective view of various portions of apackaging device in accordance with the present invention;

FIG. 89A is a fragmentary side elevation view, partly in section,illustrating various stages of operation of one embodiment of a cartonerection device in accordance with one embodiment of the invention;

FIG. 89B is a fragmentary elevation view, partly in section, of thedevice shown in FIG. 89A illustrating various stages of erecting acarton in accordance with the present invention;

FIG. 89C is a fragmentary perspective view of portions of one embodimentof a container handling apparatus in accordance with the presentinvention;

FIG. 89D is a fragmentary perspective view illustrating a portion of theoperation of the automated packaging device in accordance with oneembodiment of the present invention;

FIG. 89E is a fragmentary perspective view illustrating part of theoperation of the packaging device in accordance with one embodiment ofthe present invention;

FIG. 89F illustrates a side elevation sectional view of variousoperations of a portion of the packaging device in accordance with oneembodiment of the present invention;

FIGS. 89G and 89H are fragmentary side elevation views showing a portionof the operation of one embodiment of a packaging device in accordancewith the present invention;

FIG. 89I is a fragmentary perspective view of a portion of a packagingdevice in accordance with one embodiment of the invention illustrating aportion of the operation of that device;

FIG. 90A is a fragmentary perspective view of one embodiment of amechanical arm assembly for the packaging device in accordance with thepresent invention;

FIG. 90B is a fragmentary perspective view showing portions of themechanical arm and elevator assembly of a packaging device in accordancewith the present invention;

FIG. 90C is a fragmentary perspective view illustrating a portion of theembodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

FIG. 90D is a fragmentary perspective view illustrating a portion of theembodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

FIG. 90E is a fragmentary perspective view illustrating a portion of theembodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

FIG. 90F is a fragmentary perspective view illustrating a portion of theembodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof; and

FIG. 91 illustrates a fragmentary perspective sectional view of apackaging device in accordance with the present invention illustratingan alternate embodiment of a filled French fry container holding devicein accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION General

In accordance with the present invention, an automated food processingsystem and method is provided. The automated food processing system andmethod in accordance with the invention allows food to be dispensed,fried and packaged in a suitable container or alternatively dispensed toa food holding area for subsequent processing by a human operator.

Referring to the Figures generally, where like reference numerals referto like elements, and in particular to FIGS. 1 and 3 and 74 and 76,there is illustrated an automated food processing system 100 inaccordance with the invention and an automated food processing system1100 in accordance with the invention. Automated food processing systems100 and 1100 include a food dispensing device 200, 1200, a fry device400, 1400 and a food packaging device 600, 1600, respectively. Inaccordance with one embodiment of the present invention, each ofdispensing, fry and packaging devices 200, 400 and 600, and 1200, 1400and 1600, respectively, can be constructed and are sometimes illustratedin “modular” construction or form. By “modular” construction or form itis meant that dispensing, fry and packaging devices 200, 400 and 600,and 1200, 1400 and 1600, respectively, can exist and be contained inseparate cabinets, for example, and also operate independently of theother devices. Thus, if one of dispensing, fry and packaging devices200, 400 and 600, or 1200, 1400 and 1600, respectively, are inoperativeor are otherwise deactivated, the function of the deactivated orinoperative device can be performed manually. For example, food to befried could be manually dispensed in place of dispensing device 200 or1200. Alternatively, food to be fried could be fried in a conventionalfry vat after being dispensed from dispensing device 200 or 1200 inplace of using fry device 400 or 1400 and food that is dispensed andfried in dispensing and fry devices 200 and 400, respectively, could, inturn, be packaged manually, for example.

To facilitate such modular construction and use, each of dispensing, fryand packaging devices 200, 400 and 600, and 1200, 1400 and 1600,respectively, can be contained in a separate wheeled cabinet, 202, 402and 602, and 1202, 1402 and 1602, respectively, as illustrated in FIGS.1 and 74. Alternatively, dispensing, fry and packaging devices 200, 400and 600, and 1200, 1400 and 1600, respectively, could be mounted as asingle unit or in a single cabinet or in “non-modular form,” as desired,or more than one of such devices 200, 400 and 600 or 1200, 1400 and1600, could be so mounted or combined.

A suitable control system for the dispensing, fry and packaging devicesis also provided. As will be described more completely hereafter, in oneembodiment, the control system includes a central control system 110 or1110 that can interface with a point-of-sale system 112 or 1112,respectively. The central control system will communicate with separatesubcontrol systems 114, 116 and 118 or 1114, 1116 and 1118,respectively, one for each of the dispensing, fry and packaging devices200, 400 and 600 and 1200, 1400 and 1600, respectively. Alternatively, asingle central control system (not shown) could be utilized in place ofindividual control systems for each of devices 200, 400 and 600 ordevices 1200, 1400 and 1600. Similarly, as another alternative, a singlecentral control system could be utilized to control the overalloperation of automated food processing system 100 or 1100 as well ascontrolling the individual functions and aspects of dispensing, fry andpackaging devices 200, 400 and 600 or 1200, 1400 and 1600, respectively.

The basic operations of dispensing devices 200 and 1200, fry devices 400and 1400 and food packaging devices 600 and 1600 will now be brieflydiscussed and discussed in detail hereafter.

Briefly, dispensing devices 200 and 1200 each function to dispense aquantity of food to be fried to fry device 400 or 1400. In one aspect ofthe invention, any suitable food dispensing device can be utilized.Dispensing devices 200 and 1200 can include a cabinet 202 or 1202,respectively, to house the components of dispensing device 200 or 1200.In one embodiment, cabinet 202 or 1202 will be refrigerated, preferablybelow 32° F. so that the food contents therein will remain frozen. Thisallows the food stored in dispensing devices 200 or 1200 to remaintherein for a long period of time, much longer than if the contents weremerely refrigerated (above freezing) or merely at room temperature.

In the illustrated embodiments, dispensing devices 200 and 1200 includean uncooked bulk food dispensing container 204 and 1204, respectively.Uncooked bulk food dispensing containers 204 and 1204 may be utilizedfor food such as French fries or chicken nuggets, for example. Othertypes of food may also be contained in a dispenser such as uncooked bulkfood dispensing containers 204 and 1204. Typically, those types of foodwould be in the form of relatively small pieces compared to relativelylarge food pieces such as chicken patties, for example.

For relatively large food pieces, a large food dispensing container isutilized. In one embodiment, the large food dispensing container is inthe form of magazine food dispensers 206 and 1206.

Food dispensed from a dispenser of dispensing devices 200 and 1200 isdeposited on a conveyor 208 or 1208, respectively, that, in turn,directs the deposited food to a secondary or dump container 210 orbottomless container 1210 for subsequent discharge from dispensingdevice 200 or 1200, respectively.

In the illustrated embodiments, uncooked bulk food dispensing containers204 and 1204, magazine food dispensers 206 and 1206, conveyors 208 and1208 and secondary containers 210 and 1210 are contained in cabinet 202or 1202, respectively, which is a refrigerated environment, preferablymaintained below freezing (32° F. or lower).

While any suitable conveyor can be utilized in one aspect, conveyors 208and 1208 are each preferably a vibratory conveyor, vibrated by asuitable vibratory mechanism that vibrates conveyor bodies 214 and 1214,respectively. Conveyor bodies 214 and 1214 may each take the form of asuitably shaped tray, for example.

By containing the foregoing components in a refrigerated and preferablyfrozen environment, consistency in food preparation and dispensing isachieved, thereby contributing to the overall efficient, effective anduniform performance of automated food processing systems 100 and 1100.

Secondary containers 210 and 1210 can be of a form as desired andincludes suitable weighing mechanisms 216 and 1216, respectively, topermit a determination of the quantity of food contained in secondarycontainers 210 and 1210. Weighing mechanisms 216 and 1216 can each beany suitable device to weigh the contents or otherwise determine theamount of food in secondary container 210 or 1210. Weighing mechanisms216 and 1216 may comprise a load cell or a mechanism for determining thevolume of food deposited into the respective one of secondary containers210 and 1210, for example. In this manner, the amount of food that ischarged to one of fry devices 400 and 1400 at a particular time can bedetermined. In addition, weighing mechanisms 216 and 1216 can beoperated during operation of conveyors 208 and 1208, respectively, andthe operation of conveyors 208 and 1208 continued until a desired amountof food is deposited in secondary container 210 or 1210. In this manner,a precise amount of food can be delivered to a respective one ofsecondary containers 210 and 1210, thereby permitting consistency anduniformity in the portion of food that is delivered to fry device 400 or1400. This is also important to ensure that a sufficient quantity offood is being cooked by automated food processing systems 100 and 1100.

Prior to activation of dumping mechanisms 218 or 1218, discharge doors220 or 1220 of cabinets 202 and 1202, respectively, are opened byoperation of a door opening device which can be any suitable device asdesired and in one illustrated embodiment is a cylinder 222 attached todischarge door 220 and movable up and down in the direction of arrow B.A respective one of discharge doors 1220 of dispensing device 1200 isopened by lateral movement of the associated one of secondary container1210, as illustrated in, for example, FIG. 76. Cabinets 202 and 1202 arepreferably insulated with a suitable insulating material 224 and 1224that are also provided in discharge doors 220 and 1220. The provision ofa suitable insulating material is important, particularly sincedispensing devices 200 and 1200 will typically be located proximate oradjacent one of fry devices 400 and 1400 that operate at a substantiallyelevated temperature, thereby typically generating substantial heat.

In the illustrated embodiments, dispensing devices 200 and 1200 eachincludes four dispensing lanes from which food is discharged fromdispensing devices 200 and 1200, respectively, and to a suitablelocation such as one of fry devices 400 and 1400. After dispensingthrough discharge door 220, cylinder 222 is activated to close dischargedoor 220. Similarly, dumping mechanism 218 of secondary container 210 isactivated to return secondary container 210 to its upright position toreceive more food.

For dispensing device 1200, after dispensing through one of doors 1220,as the respective one of secondary containers 1210 is retracted, theassociated one of doors 1220 closes by gravity, without the need for aseparate closing mechanism.

Each of fry devices 400 and 1400 includes, respectively, a fry wheel404, a fry vat 406 for containing and heating a suitable cooking oil anda drive mechanism 408 for suitably rotating fry wheel 404. It is to beunderstood that in accordance with one aspect of the invention anysuitable frying device can be utilized.

In the illustrated embodiment of FIGS. 3, 11-16 and 74, fry devices 400and 1400 include a plurality of, in this case four, separate fry wheels404, 410, 412 and 414, as well as four separate fry vats 416, 406, 420and 418 and a separate drive mechanism 408 for each fry wheel, eachdedicated to a particular one of fry wheels 404, 410, 412 and 414.

In various embodiments, a separate drive mechanism is provided for eachof fry wheels 404, 410, 412 and 414 and can be suitably located incabinet 402 or 1402, preferably in a location that is above the level ofcooking oil present in the associated one of fry vats 416, 406, 420 and418, respectively. Fry module 1400 is similar to fry module 400, exceptthat fry module 1400 includes a foam deck and overflow arrangement ashereafter described.

The suitable rotation of each of fry wheels 404, 410, 412 and 414 can beas desired to direct food articles loaded therein down and through thefry vat until reaching the other side of the fry vat whereupon the foodarticles are discharged. The rotation can be either continuous or aperiodic incremental rotation. For example, a suitable drive mechanismcan be provided to periodically rotate fry wheel 410 in a desiredrotational increment, which may be based on the number of compartmentscontained in fry wheel 410. In the illustrated embodiments of FIG. 13,for example, fry wheel 410 comprises eight food compartments 422, 424,426, 428, 430, 432, 434, and 436. Each of food compartments 422-436 is aperimeter food compartment and open to the perimeter or exterior of frywheel 410. Each of fry wheels 404, 412 and 414 can be similarlyconfigured.

As described in more detail hereafter, each of compartments 422-436 isformed from a perforated curved compartment forming member 510.

In the rotation of fry wheel 410, a periodic incremental rotation can bebased upon 360° divided by the number of compartments. Thus, forexample, in the illustrated embodiments of FIG. 13 and FIG. 76, eachperiodic rotation would consist of a rotation of 360° divided by eightcompartments or a periodic rotation increment of 45°. Thus, asillustrated in FIG. 13, the food contained, in this case French fries,in compartments 424-430 would remain in cooking oil 454 contained in fryvat 406 for all or part of four incremental rotations, after which thefood would be discharged from fry wheel 410 in the next incrementalrotation thereof. For example, as illustrated in FIG. 13, compartment422 is ready to receive a charge of food to be fried, compartment 424has a charge of food that has been just immersed in cooking oil 454.Cooking oil 454 is at a level H as illustrated in FIG. 13, which isdependent upon the amount of food contained in compartments 422-436 thatare submerged in cooking oil 454.

Similarly, compartment 426 has food contained therein that has gonethrough two incremental 45° rotations of fry wheel 410, compartment 428has food contained therein that has undergone three incrementalrotations and food compartment 430 has food contained therein that hasundergone four incremental rotations of fry wheel 410 and compartment432, which is now empty, has discharged the food contained therein uponthe last incremental rotation of fry wheel 410. Thus, upon the nextincremental rotation of fry wheel 410, which is in the clockwisedirection as shown by arrow B of FIG. 13, the food contained in foodcompartment 430, which in this case is a quantity of French fries 455,will be discharged from compartment 430 to the food packaging devicewhich is hereafter briefly described.

Upon discharge of food, which in this case is a quantity of French friesfrom one of compartments 422-436 of a fry wheel, such as fry wheel 410as illustrated in FIGS. 3 and 76, the food is deposited onto arespective one of inlet chutes 604 or 1604 of food packaging devices 600and 1600.

For packaging module or device 600, from inlet chute 604, the food frominlet chute 604 and previously received from fry wheel 410 is depositedinto dispensing member 606. Typically, dispensing member 606 will becompartmented into a plurality of compartments that are arrayed alongthe periphery of rotatable food dispensing member 606.

Rotatable food dispensing member 606 has a discharge location todischarge the food deposited therein. The discharge location isgenerally located towards an upper portion of rotatable food dispensingmember 606. A food dispensing chute mechanism 608 is positioned toreceive cooked food from the discharge location of rotatable fooddispensing member 606. In a preferred embodiment, food dispensing chutemechanism 608 incorporates a device for weighing or otherwisedetermining the quantity of food that has been deposited into fooddispensing chute mechanism 608. This ensures that when food is dispensedfrom food dispensing chute mechanism 608 a minimum quantity of food willbe dispensed, thereby ensuring that a container 611 or other packagethat is to receive the food from mechanism 608 will receive a desiredcharge.

Food packaging device 600 preferably also includes a suitable automatedcontainer handling system 610. Automated container handling system 610is capable of, in a preferred embodiment, selecting container 611 of adesired size, retrieving and grasping container 611, erecting unerectedcontainer 611 into an erected form and holding the erected container 611in position to receive food dispensed from food dispensing chutemechanism 608.

After food container 611 receives food from food dispensing chutemechanism 608, automated container handling system 610 is capable ofmoving container 611 having food deposited therein to a containerreceiving receptacle 612 which receptacle 612 can be transported via aconveyor system 614 to a desired location for subsequent pickup ofcontainer 611 having food contained therein by a human operator, forexample.

Preferably, a food overflow collection member is provided to collect anyfood dispensed by food dispensing chute mechanism 608 that is notdeposited into container 611. In one embodiment, the overflow foodcollection device is a rotatable food collection member 613. Overflowfood collection member 613 functions to collect food dispensed by fooddispensing chute mechanism 608 that is not received in container 611 andto recycle food collected by overflow food collection member 613 intofood dispensing chute mechanism 608 for subsequent dispensing to acontainer in a first-in, first-out manner so that overflow food ispromptly recycled to dispensing chute 608 for dispensing to a container.

Preferably, food packaging device 600 is configured to include aprovision by which food contained in packaging device 600 is routed towaste where it is not desired to dispense such food into a foodcontainer. Such a condition could arise, for example, if food is heldfor too long a period in food packaging device 600. This function may beaccomplished, for example, by providing a waste discharge location whichcan be in the form of a waste chute 615 to which food from rotatablefood dispensing member 606 and overflow food collection member 613 canbe directed. In one embodiment, chute mechanism 608 is lowered andmember 606 is rotated to dispense food to chute mechanism 608, which inturn dispenses into member 613. Member 613 is rotated counterclockwiseto deliver food to waste chute 615. This process can be continued untilall of the food in device 600 is so emptied, if desired.

Preferably, a suitable structure for applying a desired quantity ofseasoning to food contained in food packaging device 600 is provided. Inthe embodiment illustrated in FIG. 3, a food seasoning device 616 isprovided. Food seasoning device 616 can be any suitable seasoning deviceas desired. In one embodiment, food seasoning device 616 dispenses adesired quantity of seasoning from a bulk storage container through adelivery tube and onto food located in rotatable food dispensing member606.

Preferably, and in the embodiment illustrated in FIG. 3, a foodseasoning device 616 is provided that directs a desired quantity ofseasoning onto food that is contained in a bottom portion of rotatablefood dispensing member 606 and inlet chute 604 via a seasoningdispensing head 618.

Preferably, conveyor system 614 is composed of a raceway 620 that is anendless loop around the periphery of the top surface of cabinet 602 offood packaging device 600, which in one embodiment can be a modular,wheeled cabinet. Conveyor system 614 causes container receivingreceptacle 612 to travel around raceway 620 to a food container pickuplocation 622 where a human operator can pickup food containers havingfood therein. Preferably, conveyor system 614 includes structure forstopping movement of a container/receiving receptacle 612 at apredetermined location when carrying a food container, such as at foodcontainer pickup location 622. Such structure in one embodiment maycomprise a gate structure 928 or 928′ of FIG. 45 and FIGS. 25-27,respectively, that extends across at least a portion of raceway 620 inthe vicinity of the predetermined location. Any suitable type of barrierstructure can be utilized to prevent the desired movement. Mostpreferably, gate structure 928 or 928′ will be located at a height thatis above the top of the receptacle when located on conveyor system 614so that movement of container/receiving receptacle 612 is prevented orstopped only for a receptacle 612 that has a food container 611 disposedthereon. Note that the pickup location can be configured as desired andslightly different configurations 622 and 622′ are shown in FIG. 45 andFIGS. 25-27, respectively.

The basic elements of food packaging device 1600 may include an inletchute 1604, preferably a salting device 1606, preferably gates 1608 and1610 operatively associated with inlet chute 1604, a holding bin 1612for French fries, an automated French fry container filling device 1614that includes an automated mechanical arm 1616 and a carriage 1618, afilled French fry container drop-off location and holding structure 1620and preferably, a container handling system 1622 typically for cartonstorage, carton erection and handling, suitable for use with French frycontainer filling device 1614, as hereafter described in further detail.As shown in FIG. 74, an inlet chute 1603 is provided to feed cooked foodproducts into holding bin 1603′ received from fry wheel 404, typicallyfor food items such as chicken filets, fish filets or chicken nuggets,for example, received from lane 1240. Bin 1602′ may be heated, ifdesired.

Briefly, the operation of packaging device or module 1600 is as follows.

Food from fry module 400 or 1400, such as from fry wheel 410 isdeposited onto the inlet portion of inlet chute 1604. Typically, gate1608 will be positioned to prevent the passage of French fries past gate1608. Salting device 1606 then operates to apply a desired quantity ofsalt or other seasoning to the bulk amount of French fries on inletchute 1604 contained upstream of gate 1608. Salting device 1606 can belaterally moved along a carriage 1606′ during dispersing of the salt orother seasoning to help ensure seasoning coverage over the entirequantity of French fries in inlet chute 1604 that are upstream of gate1608. Alternatively, one or more salter devices 1606 can be mounted in adesirable stationary position above inlet chute 1604 or some otherdesirable location without a carriage. Salter device 1606 is similar tofood seasoning device 616 described in detail hereafter.

Gate 1608 preferably is composed of reciprocable fingers that can beraised and lowered relatively rapidly so that as the bulk amount ofFrench fries travel past gate 1608, the fingers provide a declumpingaction on the French fries. Gate 1610 can be in a position to retain theFrench fries at a lower portion of inlet chute 1604, such as ifadditional French fries are not needed in holding bin 1612. When gate1610 is in an open or lowered position, French fries in the low portionof chute 1604 are free to travel into holding bin 1612.

A vibratory mechanism 1624 as shown in FIG. 76 may also be associatedwith inlet chute 1604 so that inlet chute 1604 vibrates to facilitatethe passage of fries along inlet chute 1604 and into holding bin 1612.

French fry container filling device 1614 operates to fill erected Frenchfry containers that typically will be individual portion-sized Frenchfry containers, and is composed of a multilink mechanical arm 1616.Mechanical arm 1616 has an end-of-arm tool 1626 that is capable ofgrasping a French fry container, scooping it into French fries containedin holding bin 1612 to fill the French fry container with French fries,relatively gently shaking the filled French fry container to seat theFrench fries in the container and to dislodge any loosely containedFrench fries and depositing the filled French fry container at adrop-off location. Preferably, the filled French fry container is shakenover the holding bin so that French fries that are shaken from thecontainer fall into holding bin 1612 and so that French fries becomemore firmly seated in the French fry container.

In one embodiment, automated mechanical arm 1616 can be configured andoperated to mimic the arm, wrist and hand action of a human operator inscooping French fries into a French fry container to fill the containerand shaking the filled French fry container to remove loosely containedFrench fries and to more firmly seat French fries contained in thecontainer.

Food packaging device 1600 preferably also includes a suitable containerhandling system 1622. Container handling system 1622 is capable of, in apreferred embodiment, selecting a container 611 of a desired size,retrieving and grasping container 611, erecting unerected container 611into an erected form and delivering erected container 611 to French frycontainer filling device 1614.

Referring to FIGS. 2 and 75, there are illustrated various alternateembodiments of automated food processing systems 101 and 1101 inaccordance with the invention. Automated food processing systems 101 and1101 include, respectively, a food dispensing device 201, 1201 which issimilar to food dispensing devices 200 and 1200, previously brieflydescribed, where like reference numerals represent like elements. Fooddispensing devices 201 and 1201 include fewer uncooked bulk fooddispensing containers 204, 1204 and additional magazine food dispensersthat are similar to magazine food dispensers 206 and 1206, previouslyreferred to. Otherwise, dispensing devices 201 and 1201 are similar todispensing devices 200 and 1200, previously described, respectively.

Automated food processing systems 101 and 1101 also include fry devices400 and 1400, respectively, which have been described.

One primary distinction between automated food processing systems 100and 1100 and automated food processing systems 101 and 1101 is thatautomated food processing systems 101 and 1101 do not include anautomated packaging device such as automated packaging devices 600 or1600. In place of food packaging devices 600 or 1600, a food storagedevice 635 is provided, which may be contained on a movable cart 635′.Food storage device 635 allows food cooked by food frying devices 400 or1400 to be stored in a heated environment for subsequent manualprocessing. As configured in FIGS. 2 and 75, food storage device 635includes separate heated product receiving receptacles 637, 639, 641 and643. Each receptacle 637, 639, 641 and 643 is dedicated to receivingfood from a respective one of fry wheels 410, 412, 414 and 404,respectively. In addition, each receptacle 637-643 can have placedtherein a suitable container to receive food, such as handled trays 645,647, 649 and 651.

As illustrated in FIG. 2, a food item F is being discharged from frywheel 414 down a chute 653 and into handled tray 649 contained withinheated receptacle 641. Food item F can be stored therein for a period oftime until it is ready for subsequent processing.

It is to be understood that other devices or modules can be used inplace of any of food dispensing device 200, fry device 400 and foodpackaging device 600. For example, referring to FIGS. 74-91, there areillustrated alternate embodiments, namely, dispensing device or module1200, fry device or module 1400 and packaging device or module 1600.

Food Dispensing Device

Referring to the Figures generally and in particular to FIGS. 1-10 and74-84, there are illustrated various embodiments of food dispensingdevices and portions thereof in accordance with the invention.

In two embodiments, food dispensing devices 200 and 1200 are illustratedor partially illustrated in each of FIGS. 1 and 3-8 and 74 and 76-84.Food dispensing device 200 includes a cabinet 202, bulk uncooked fooddispensing containers 204, 205 and 207, magazine food dispensers 206,209, 211 and 213, and a suitable conveyor system for each lane 234, 236,238 and 240 of food dispensing device 200. Similarly, food dispensingdevice 1200 includes a cabinet 1202, bulk uncooked food dispensingcontainers 1204, 1205 and 1207, magazine food dispenser 1206, 1209,1211, 1213 and 1215, and a suitable conveyor system for each lane 1234,1236, 1238 and 1240 of food dispensing device 1200. Any suitable numberof magazine dispensers can be used for a particular lane, such as one,two, three, four, five or more, and the illustrated embodiment of fiveis merely an example. As configured in FIGS. 1 and 74, for example,lanes 234, 1234 receive material from bulk hoppers 204, 1204, lanes 236,1236 receive food material from bulk hoppers 205, 1205, lanes 238, 1238receive food material from bulk hoppers 207, 1207 and lanes 240, 1240receive dispensed food from magazine food dispensers 206, 209, 211 and213, and 1206, 1209, 1211, 1213 and 1215, respectively, as will bedescribed hereinafter in greater detail, particularly with respect tofood dispensing device 201 of FIG. 2, for example. Food dispensingdevice 1200 is similar to food dispensing device 200, except that device1200 has a different secondary container, exterior doors and differencesin the conveyor apparatus, as hereafter described.

Each lane 234, 236, 238 and 240 or 1234, 1236, 1238 and 1240 dispensesfood that is subsequently directed to fry wheels 410, 412, 414 and 404,respectively.

The components of lane 238 will now be described in detail and it is tobe understood that the components of lanes 234 and 236 are similar. Lane238 includes uncooked bulk food dispensing container 207 and a foodhandling system 242 which in this embodiment is identical for each lane234, 236, 238 and 240 as well as for each lane of food dispensing device201. It should be noted that food handling system 242, as for example,illustrated in FIGS. 3-6 is depicted with respect to lane 240 and thatfood handling system 242 is the same for each lane 234, 236, 238 and240.

Food handling system 242 includes conveyor system 208, secondarycontainer 210, weighing mechanism 216 and dumping mechanism 218.Conveyor system 208 includes vibratory mechanism 212 and conveyor body214.

Uncooked bulk food dispensing container 204 can be of a shape anddimension generally as desired. Preferably, uncooked bulk fooddispensing container 204 has an upper opening to permit a supply of foodto be placed in uncooked bulk food dispensing container 204. Upperopening 244 as illustrated is located in an upper rear portion ofuncooked bulk food dispensing container 204 and can be convenientlyaccessed via a rear door 246 of cabinet 202. Rear door 246 preferably isinsulated with suitable insulation material 224.

Uncooked bulk food dispensing container 204 is composed of a pair ofopposed upper sidewalls 248, a pair of generally opposed lower sidewalls250 and front and rear walls 252 and 254, respectively, which connecttogether upper sidewalls 248 and lower sidewalls 250 to provide uncookedbulk food dispensing container 204. Front wall 252 includes a lowerportion 252′ that extends inwardly from top to bottom to furtherfacilitate discharge of food contained in uncooked bulk food dispensingcontainer 204. Preferably, lower generally opposed sidewalls 250 areslightly indented from top to bottom to facilitate the discharge of foodthat may be contained therein.

Uncooked bulk food dispensing container 204 includes a bottom opening256 that permits the discharge of food contained therein. Bottom opening256 can be configured as desired and in the illustrated embodiment theentire bottom of uncooked bulk food dispensing container 204 is open. Inthe illustrated embodiment, uncooked bulk food dispensing container 204is particularly suited for use with food such as French fries andchicken nuggets as well as other types of food of relatively small size.

Uncooked bulk food dispensing container 204 is suitably mounted withincabinet 202. While a suitable mounting structure can be utilized, it ispreferred to utilize a structure that will minimize heat transfer fromthe exterior and through cabinet 202 to uncooked bulk food dispensingcontainer 204, particularly where cabinet 202 is refrigerated,especially where temperatures below freezing are utilized. In thatregard, front mounting bracket 258 and rear mounting bracket 260 eachare configured to minimize heat transfer from cabinet 202 to uncookedbulk food dispensing container 204. In that regard, front mountingbracket 258 and rear mounting bracket 260 include openings, 258′ and260′, respectively, to minimize such heat transfer and to maximizeairflow around the containers 204, 205, 207 and dispensers 206, 209, 211and 213. Similarly, materials of low thermal conductivity can also beutilized, if desired, for brackets 258 and 260. Generally, to minimizeheat transfer and to maximize airflow, the surface area contact andcross-sectional area of mounting brackets 258 and 260 should beminimized to reduce heat transfer and “hot spots” on uncooked bulk fooddispensing container 204.

As illustrated in FIGS. 3 and 4, for example, food contained in uncookedbulk food dispensing container 204 passes through bottom opening 256 andonto conveyor body 214 which in the illustrated embodiment is a suitablydimensioned pan. Conveyor body 214 is suitably mounted to vibratorymechanism 212 to effect vibration of conveyor body 214 as well as foodcontained therein and food contained in uncooked bulk food dispensingcontainer 204, and in particular the lower portion of container 204.This vibration facilitates the discharge of food from uncooked bulk fooddispensing container 204 and causes food contained in conveyor body 214to travel in the direction of arrow G. Any suitable conveyor system canbe used in accordance with one aspect of the invention.

A preferred type of vibratory mechanism is available from FMCTechnologies, Inc. of Chicago, Ill. marketed under the model F-010-B andDF-010-B. Vibratory mechanism 212 is preferably an electromagneticvibrating mechanism. Vibratory mechanism 212 in one embodiment producesa vibrating stroke at the surface of conveyor body 214. The strokeresults from the action of an electromagnet that pulls conveyor body 214sharply down and backward and then allows it to spring up and forward.Typical vibratory mechanisms of this type run at about 3,600vibrations/minute at 60 Hz power. The power of the vibrating stroke canbe controlled by a suitable drive module as is known in the art. In oneembodiment, vibratory mechanism 212 can be operated at about 85% of fullpower during filling of secondary container 210 with food. For the firstpart of a fill cycle of secondary container 210, vibratory mechanism 212can be run continuously, then pulsed by turning its power on and offperiodically so that vibratory mechanism 212 operates about 50% of thetime to finish filling secondary container 210 with a desired quantityof food, thereby providing better control on the last part of the foodcharged to secondary container 210.

Food dispensing device 200 preferably includes a suitable mechanism todetermine the weight or volume of a charge of food delivered by conveyor208 to secondary container 210. The amount may be determined either byweight or volume, for example. In the illustrated embodiment, weighingmechanism 216 is operatively interfaced with secondary container 210 toprovide an indication of the weight of food contained in secondarycontainer 210. The weight sensed in secondary container 210 by weighingmechanism 216 is communicated with subcontrol system 114 of fooddispensing device 200. Subcontrol system 114 monitors and controls theoperative functions of food dispensing device 200 as hereinafterdescribed in greater detail.

Optionally, a level sensor can be employed in uncooked bulk fooddispensing container 204 to provide an indication of the amount of foodstored therein that is available for dispensing. Any suitable levelindicator known in the art can be utilized in accordance with theinvention such as photoelectric, weight, turning fork and others, forexample.

Secondary container 210 can be considered as a dump container and hasassociated therewith, dumping mechanism 218 for rotating secondarycontainer 210 through an arc as indicated by arrow B sufficiently todump the contents of secondary container 210. Any suitable dumpingmechanism can be utilized. Illustrated dumping mechanism 218 includes adump cylinder 264 that is secured to a base 266. Dump cylinder 264 canselectively rotate a drive gear or wheel 268 that, in turn, isoperatively associated with a follower gear or wheel 270 to causerotation of follower gear or wheel 270. Secondary container 210 isrigidly secured to follower gear or wheel 270 so that when follower gearor wheel 270 is rotated by drive gear or wheel 268 secondary container210 is rotated through an arc that causes secondary container 210 torotate forward to a dumping position as illustrated in phantom lines inFIG. 3 indicated by reference numeral 210′. Such movement is caused byextension of dump cylinder 264. Similarly, retraction of dump cylinder264 moves secondary container 210 from the dump position indicated byreference numeral 210′ to the upright position indicated by referencenumeral 210 in FIG. 3 where secondary container 210 is ready to receivea charge of food from conveyor 208, which in the illustrated embodimentthe food is French fries FF.

An alternative embodiment for secondary container 210 is illustrated inFIG. 4A. Secondary container 210″ is composed of a pair of opposedspaced apart sidewalls 211′ (only one sidewall 211′ is illustrated andis depicted in a half-moon configuration) and a pair of sidewalls 213 aand 213 b, oriented in a V-shaped relationship when container 210″ isconfigured to receive food from conveyor body 214. Sidewall 213 a ismounted for pivotal movement about apex 215 of sidewalls 213 a and 213b. Such movement is accomplished by a drive mechanism similar tocylinder 264, drive gear 268 and driven gear 270, which in thisembodiment are cylinder 264′, drive gear 268′ and driven gear 270′,which gear 270′ is attached to sidewall 213 a. When cylinder 264′ isextended, sidewall 213 a is caused to pivot downwardly as indicated byarrow AA to the position of sidewall 213 a shown in phantom, therebycausing the contents (French fries FF) of container 210″ to be dumped.Sidewalls 211′ act as sidewall guides for sidewalls 213 a and 213 b whensidewall 213 a is in a lowered position, in which case sidewalls 213 aand 213 b act as a chute or slide.

The components of lane 1234 will now be described in detail and it is tobe understood that the components of lanes 1236 and 1238 are similar.Lane 1234 includes uncooked bulk food dispensing container 1204 and afood handling system 1242 which in this embodiment is identical for eachlane 1234, 1236, 1238 and 1240 as well as for each lane of fooddispensing device 1201. It should be noted that food handling system1242 and components thereof, as for example, illustrated in FIGS. 76-84is depicted with respect to lane 1234 and that food handling system 1242is generally the same for each lane 1234, 1236, 1238 and 1240 unlessotherwise noted.

Food handling system 1242 includes conveyor 1208, secondary container1210, weighing mechanism 1216 and dumping mechanism 1218. Conveyorsystem 1208 includes vibratory mechanism 1212 and conveyor body 1214.

Uncooked bulk food dispensing container 1204 can be of a shape anddimension generally as desired and can be similar to container 204previously described. Preferably, uncooked bulk food dispensingcontainer 1204 has an upper opening to permit a supply of food to beplaced in uncooked bulk food dispensing container 1204. Upper opening1244 as illustrated is located in an upper rear portion of uncooked bulkfood dispensing container 1204 and can be conveniently accessed via arear door 1246 of cabinet 1202. Rear door 1246 preferably is insulatedwith suitable insulation material 1224.

Uncooked bulk food dispensing container 1204 is similar to container 204previously described.

Uncooked bulk food dispensing container 1204 includes a bottom opening1256 that permits the discharge of food contained therein. Bottomopening 1256 can be configured as desired and in the illustratedembodiment the entire bottom of uncooked bulk food dispensing container1204 above conveyor body 1214 is open. In the illustrated embodiment,uncooked bulk food dispensing container 1204 is particularly suited foruse with food such as French fries and chicken nuggets as well as othertypes of food of relatively small size.

Uncooked bulk food dispensing container 1204 is suitably mounted withincabinet 1202, such as described with respect to food dispensingcontainer 204.

As illustrated in FIGS. 76 and 77, for example, food contained inuncooked bulk food dispensing container 1204 passes through bottomopening 1256 and onto conveyor body 1214 which in the illustratedembodiment is a suitably dimensioned pan. Conveyor body 1214 may have aplurality of spaced apart holes in a bottom portion thereof (shown inFIG. 79 with respect to conveyor 1214′) to permit ice crystals orunwanted small particles of food to pass therethrough so that suchmaterial is not dispensed to fry module 1400. Any suitable or desiredarray of holes or apertures can be utilized as desired. Typically, thehole size will be about 0.25 inches or less and may be about 0.125inches or less. Below and at the downstream bottom end of conveyor body1214 is located secondary container 1210, which is positioned to receivefood items from conveyor body 1214 of conveyor 1208. Conveyor body 1214is suitably mounted to vibratory mechanism 1212 to effect vibration ofconveyor body 1214 as well as food contained therein and food containedin uncooked bulk food dispensing container 1204, and in particular thelower portion of container 1204. This vibration facilitates thedischarge of food from uncooked bulk food dispensing container 1204 andcauses food contained in conveyor body 1214 to travel in the directionof arrow G′. Any suitable conveyor system can be used in accordance withone aspect of the invention. The same type of vibratory mechanism can beused as previously described with respect to vibratory mechanism 212.

In accordance with another embodiment of the invention, a regulatingdevice which may be an elongated rotatable device, may be provided at alower portion of bulk food dispensing container 207 or 1204, orotherwise located between the bottom or a bottom portion of container207 or 1204 and above or along an upper portion of conveyor 214 or 1214.The regulating device limits the quantity of French fries or other foodthat is delivered to conveyor 214 or 1214 so that conveyor 214 or 1214does not get overloaded or jammed with food items. Such a device isillustrated in FIGS. 77A and 77B and includes an elongated vane device1257, rotatable by a suitable motor device (not shown). In oneembodiment, vane device 1257 can be rotated about 120° in eitherdirection and after rotating, food (e.g., French fries) is caused to bedispensed into conveyor 214 or 1214. When additional food is needed forconveyor 214 or 1214, which can be determined by a suitable sensor,which can be an optical sensor or a load cell associated with conveyor214 or 1214, vane device 1257 is rotated 120° in the motor drive in theopposite direction. The 120° rotation typically is accomplished in about2 seconds, for example.

As illustrated in FIGS. 77A and 77B, vane device 1257 is composed ofthree equally spaced apart vanes or paddles 1257 a-c, mounted to acentral triangular section 1259. Vane device 1257 can be convenientlyremoved from bulk food dispensing container 1204′, through hinged accessdoor 1261, as illustrated in FIGS. 77A and 77B, which can be opened andclosed by rotation in the direction of arrows OP and CL, respectively. Asupport 1265 for one end of vane device 1257 is provided on an interiorportion of door 1261 as shown in FIG. 77B. A suitable aperture 1263 isprovided through container 1204′ for the motor device for vane device1257, as shown in FIG. 77B with vane device 1257 removed.

Container 1204′ can be otherwise similar to container 1204 and can beconstructed of, for example, transparent walls 1267, 1269, 1271 and 1273as illustrated in FIGS. 77A and 77B, with front wall 1275 being metal oranother suitable material.

Food dispensing device 1200 preferably includes a suitable mechanism todetermine the weight or volume of a charge of food delivered by conveyor1208 to secondary container 1210. The amount may be determined either byweight or volume, for example. In the illustrated embodiment, weighingmechanism 1216 is operatively interfaced with secondary container 1210to provide an indication of the weight of food contained in secondarycontainer 1210. The weight sensed in secondary container 1210 byweighing mechanism 1216 is communicated with subcontrol system 1114 offood dispensing device 1200. Subcontrol system 1114 is similar tosubcontrol system 114 and monitors and controls the operative functionsof food dispensing device 1200 as hereinafter described in greaterdetail.

Optionally, a level sensor can be employed in uncooked bulk fooddispensing container 1204 to provide an indication of the amount of foodstored therein that is available for dispensing. Any suitable levelindicator known in the art can be utilized in accordance with theinvention such as photoelectric, weight, turning fork and others, forexample.

Secondary container 1210 is a bottomless box-like container having anopen top and is composed of generally upstanding sidewalls. A floor orplatform 1222 is stationary and is located beneath container 1210 whenin the retracted or home position as shown in FIG. 77. In this position,container 1210 is able to receive food items from associated conveyor1208. An elongated lip or tray 1210′ extends from back wall 1210 a ofcontainer 1210 so that when container 1210 is in the dump position, lipor tray 1210′ is located below the discharge end of conveyor body 1214so that any articles of food that may fall from the end of conveyor body1214 will be collected on lip or tray 1210′ and those items will bedeposited into container 1210 as it is retracted to the home or fillingposition. When holes are present in the bottom of conveyor 1214 or1214′, a suitably removable catch pan (not shown) is located between thebottom of conveyor 1214 or 1214′ and the top of lip 1210′ so that foodparticles or ice crystals falling through holes in the bottom ofconveyor 1214 or 1214′ do not land on lip 1210′.

Secondary container 1210 can be considered as a dump container and hasassociated therewith dumping mechanism 1218 for laterally movingsecondary container 1210 to retracted and extended positions relative tostationary floor or platform 1222 as indicated by arrows B′, B″ and B′″in FIGS. 76-78, respectively, sufficiently to open door 1220 and to dumpthe contents of secondary container 1210. Any suitable mechanism can beutilized to effect the desired lateral movement of container 1210 and asillustrated, dumping mechanism 1218 includes a dump cylinder or actuator1264 that is secured to a base 1266. Dump cylinder 1264 can selectivelylaterally translate secondary container 1210 which is secured to dumpcylinder 1264 so that when secondary container 1210 is laterally movedor translated to the left, as illustrated in FIG. 78, secondarycontainer 1210 moves forward to a dumping position. Such movement iscaused by extension of dump cylinder 1264. Similarly, retraction of dumpcylinder 1264 laterally moves secondary container 1210 from the dumpposition to the home or filling position as shown in FIG. 77 wheresecondary container 1210 is ready to receive a charge of food fromconveyor 1208, which in the illustrated embodiment the food is Frenchfries FF.

An alternative embodiment for conveyor body 1214, conveyor body 1214′,is illustrated in FIGS. 79 and 80. Conveyor body 1214′ is particularlysuitable for conveying chicken nuggets and similarly shaped types offood items. Conveyor body 1214′ has a tray-like body 1214 a and adischarge end 1214 b and an inlet portion 1214 c. Inlet portion 1214 cincludes an upwardly extending dividing member 1214 d that dividesconveyor body 1214′ into two food inlet passageways 1214 e and 1214 f.As illustrated, dividing member 1214 d is saddle-shaped. Inletpassageways 1214 e and 1214 f merge into a single passageway 1214 gwhich initially is relatively wide at portion 1214 g′ and subsequentlynarrows as passageway 1214 g progresses towards discharge end 1214 b.Such arrangement promotes declumping of the chicken nuggets contained inbulk container 204 or 1204 and permits the chicken nuggets to beconveyed in a single file orientation towards discharge end 1214 b. Thispermits effective dispensing and metering of chicken nuggets into eithersecondary container 210 or 1210. The width of passageway 1214 g afternarrowing is about the width of a single chicken nugget and may slightlyincrease if desired towards discharge end 1214 b if desired. Preferably,passageway 1214 g has a non-linear path and may be serpentine or zigzagas illustrated, which further promotes accurate dispensing of chickennuggets or other similarly shaped food articles, which could include, asnon-limiting examples, breaded shrimp, cheese nuggets and jalapenopoppers.

Passageway 1214 g may include a plurality of holes 1214 h orperforations through bottom 1214 i of conveyor body 1214′ to permitsmall unwanted ice crystals or food particles to pass therethrough sothat such items are not dispensed to fry module 400 or 1400.

Referring to FIGS. 81 and 82 there is illustrated the dispensing doorarrangement in accordance with one embodiment of the present invention.As illustrated, one door 1220, 1220 a, 1220 b and 1220 c is provided foreach respective product dispensing lane 1238, 1234, 1236 and 1240,respectively. Each of doors 1220, 1220 a, 1220 b and 1220 c are hingedat the top to close by gravity and are opened when container 1210associated with a particular one of doors 1220, 1220 a, 1220 b and 1220c is laterally translated by cylinder 1264 to a dumping position asshown in FIG. 78 with respect to door 1220 which has been opened in thedirection of arrow C′.

Door edge overlapping members 1221 a, 1221 b and 1221 c are hinged toswing open in a manner similar to doors 1220, 1220 a, 1220 b and 1220 c.Door edge overlapping members 1221 a, 1221 b and 1221 c are eachassociated with the respective adjacent doors 1220, 1220 a, 1220 b and1220 c as illustrated in FIGS. 81 and 82 and are hinged for movementsimilar to that independent of doors 1220, 1220 a, 1220 b and 1220 c,such as in the direction of arrow XX in FIG. 82. The door edgeoverlapping members provide a more complete seal between the sides ofdoors 1220, 1220 a, 1220 b and 1220 c that are not adjacent the ends ofdispensing device 1200, thereby restricting entry of water vapor to theinterior of dispensing device 1200 when doors 1220, 1220 a, 1220 b and1220 c are in a closed position. When one of doors 1220, 1220 a, 1220 band 1220 c open, the adjacent door edge overlapping members 1221 a, 1221b and 1221 c also open as shown in FIG. 81, where the opening of door1220 causes door edge overlapping members 1221 b and 1221 c to open,which can be moved independently of doors 1220, 1220 a, 1220 b or 1220 cas shown in FIG. 82.

Referring to FIGS. 83 and 84, there are illustrated various embodimentsof a declumping member in accordance with the present invention.

As illustrated in FIG. 83, which is a partial fragmentary exploded viewof dispensing device 1200 showing generally vertically extendingdeclumping member 1370 comprises a downwardly depending pin that isattached to a lower portion of bulk dispensing container 1204 or to someother suitable structure. Member 1370 is stationary and extendsdownwardly to a position just above the bottom of conveyor body 1214.Thus, when French fries or other food items are conveyed along conveyorbody 1214 which vibrates, member 1370 is stationary and tends to declumpor break apart a frozen clump or mass of French fries as they vibrateand travel past member 1370.

Referring to FIG. 84, which is a partial fragmentary exploded view ofdispensing device 1200 showing an alternate embodiment declumping member1372 that is attached to the bottom of conveyor body 1214 and extendsupwardly therefrom. French fries or other food items conveyed alongconveyor body 1214 will encounter member 1372 which will tend to declumpor break apart a clump or mass of French fries as they travel pastmember 1372.

Other configurations of declumping members may be used in place ofmembers 1370 and 1372. Any structure that tends to declump or breakapart a mass or frozen clump of French fries or similar food can beused.

Subcontrol system 114 coordinates the operation of the various functionsof food dispensing device 200 and/or food dispensing device 1200. Forexample, when food dispensing device 200 or 1200 is ready to dump acharge of food from secondary container 210 or 1210 out of fooddispensing device 200 or 1200, subcontrol system 114 activates cylinder222 (only for device 200) to open discharge door 220 thereby permittingthe food charge in secondary container 210 to be dumped by dumpingmechanism 218 through open discharge door 220. Dump cylinder 264 or 1264is extended causing secondary container 1210 of device 1200 to open door1220 and dump the contents therein to fry device 1400. After dumping ofthe food charge is completed, subcontrol system 114 causes dump cylinder264 or 1264 to be retracted thereby returning secondary container 210 or1210 to a position ready to accept a further charge of food fromconveyor system 208 or 1208. For device 200, cylinder 222 has one endrigidly secured to cabinet 202 or some other suitable location and theother end of cylinder 222 is attached to discharge door 220. Typically,discharge door 220 will have a suitable guide mechanism, which may betracks, slots or other suitable apparatus to guide discharge door 220 toits open and closed positions. Cylinder 222 is operable to move door 220up and down as indicated by arrow B in FIG. 6 to thereby open and closedischarge door 220 as desired. In the illustrated embodiment, dischargedoor 220 extends across all four dispensing lanes 226, 228, 230 and 232.If desired, a separate discharge door could be provided for each ofdispensing lanes 226, 228, 230 and 232 such as doors 1220, 1220 a, 1220b and 1220 c previously described. In addition, subcontrol system 114causes activation of cylinder 222, when present, to close discharge door220 to prevent heat from entering into cavity 272 of food dispensingdevice 200 in which the food and various dispensing mechanisms arecontained as illustrated in FIGS. 3 and 6, for example.

Food dispensing devices 200 and 1200 can contain suitable refrigerationcomponents 274 such as within a lower portion of cabinet 202 as shownschematically in FIG. 1. In accordance with the preferred embodiment offood dispensing devices 200 and 1200, refrigeration components 274provide sufficient cooling to provide a below freezing temperatureenvironment in cavity 272. Alternatively, suitable refrigerationcomponents can be provided exteriorly of cabinet 202 and even at aremote location as desired. In addition, a storage compartment 276 and astorage compartment door 278 may also be provided in cabinet 202. Anupper side access door may also be provided to permit operator access tothe interior of cavity 272 where uncooked bulk food dispensingcontainers 204 and/or magazine food dispensers 206 and/or 209, 211 and213 are located.

Referring to FIGS. 2 and 7-10, there is illustrated another embodimentof food dispensing device 201 in accordance with the present invention.

Food dispensing device 201 has many similarities to food dispensingdevice 200 previously described where like reference numerals representlike elements. Thus, food dispensing device 201 includes cabinet 202,four product dispensing lanes 226, 228, 230 and 232 with each such laneincorporating conveyor 208, secondary container 210, vibratory mechanism212, conveyor body 214, weighing mechanism 216, dumping mechanism 218,discharge door 220, cylinder 222, insulating material 224, food handlingsystem 242, upper opening 244, rear door 246, uncooked bulk fooddispensing container 204 which is associated with product dispensinglane 234, a dump cylinder 264 for each product dispensing lane, cavity272, refrigeration components 274, storage compartment 276 and a storagecompartment door 278. Product dispensing lanes 228, 230 and 232 eachhave associated therewith a plurality of magazine food dispensers280-308 arrayed to provide in the embodiment illustrated in FIG. 9 fivemagazine food dispensers per product dispensing lane in which there arethree product dispensing lanes serviced by the foregoing magazine fooddispensers. Consequently, magazine food dispensers are configured in athree-by-five array and are suspended from a magazine food dispensersupport 310 as shown in FIG. 9. Each row of three magazine fooddispensers depends from magazine food dispenser support 310 via a slideassembly 312. Slide assembly 312 is similar to a drawer slide includinga pair of first and second elongated telescoping left and right slides314 and 316, respectively. Suitable upper rollers 318 are mounted tomagazine food dispenser support 310 and lower rollers 320 depend frommagazine food dispensers 280-308 for traversing left and right elongatedtelescoping slides 314 and 316.

Suitable mounting brackets 322 are provided which depend upwardly frommagazine food dispenser support 310 for mounting to cabinet 202.

In addition, suitable mounting brackets 324 are provided which dependdownwardly from magazine food dispenser support 310 for mounting slideassembly 312 thereto allowing magazine food dispensers 280-308 to dependtherefrom.

Magazine food dispenser support 310 has a series of holes 326 and 328therein. Holes 326 can be provided to allow increased airflow andcooling. Holes 328 can also be provided to provide increased airflow andcooling for magazine food dispensers 280-308.

Each of magazine food dispensers 280-308 and 206, 209, 211 and 213briefly discussed with respect to food dispensing device 200 are similarin construction. Magazine food dispenser 206 will be discussed withrespect to FIGS. 7 and 8 and it is to be understood that the othermagazine food dispensers are of similar construction.

Magazine food dispenser 206 includes a body or housing 330 that includessidewalls 332 and 334, front walls 336 and 338 and corresponding rearwalls (not shown) and can be attached in a removable manner if desired,including in a snap-on arrangement to facilitate cleaning. Magazine fooddispenser 206 also includes a top member or cover 340 having mountedthereover a drive mechanism 342. Drive mechanism 342 includes a drivegear or wheel 344 and a driven wheel or gear 346. Depending from each ofdrive wheel or gear 344 and driven wheel or gear 346 is a spiral flightthat is vertically or generally vertically oriented relative to thelongitudinal axis of spiral flights 348 and 350. If desired, a singlespiral flight dispenser (not shown) could also be utilized.

Body 330 of magazine food dispenser 206 can include substantial openportions such as front open portion 352 and a corresponding rear openportion (not shown). Such open portions may have a cover or access doorthereover (not shown). Such open portions can be desirable to permitairflow through magazine food dispenser 206 since generally suchdispenser will be contained in a refrigerated environment and suchopenings help ensure that food contained therein remains frozen orchilled as desired. A vertical divider (not shown) can be providedbetween spiral flights 348 and 350 if desired.

A plurality of generally vertically disposed and spaced apart rods 354,356 and 358 may be provided at the front of magazine food dispenser 206adjacent spiral flights 348 and 350 and similar rods can be provided atthe back of magazine food dispenser 206. Rods 354, 356 and 358 preventfood pieces from falling out of spiral flights 348 and 350 and tomaintain spiral flights 348 and 350 in a vertical orientation.

Magazine food dispenser 206 has an open bottom 360 through which foodpieces can be dispensed during operation.

During operation, drive wheel 344 can be driven by a suitable electricmotor, such as an electric motor 362, 364 and 366 shown with respect tomagazine food dispensers 280, 282 and 284 in FIG. 9. Alternatively,other drive devices could be used, including, for example, a rotary airor hydraulic cylinder. Rotation of drive wheel 344 in a clockwisedirection causes driven wheel 346 to rotate in a counterclockwisedirection by virtue of the intermeshing or contact between drive wheelor gear 344 and driven wheel or gear 346. Such rotation causescorresponding rotation of spiral flights 348 and 350, respectively. Foodcontained by spiral flights 348 and/or 350 is moved downwardly by virtueof such rotation. When such food reaches the bottom of spiral flights348 and/or 350, respectively, such food is discharged from magazine fooddispenser 206 through open bottom 360 and onto conveyor 208 for handlingas previously described or onto conveyor 1208, for example. A singlemotor could be used to drive a plurality of dispensers 280, 282 and 284,etc. through a suitable drive mechanism (not shown).

As shown in FIG. 8, pieces of food can be contained by magazine fooddispenser 206 in two different ways. For example, individual pieces offood may each be contained by a single elongated spiral flight 348 or350 as shown with respect to food pieces F1 and F2, respectively. Foodpieces F1 and F2 can be any type of desired food and may be a food itemsuch as a hash brown, an individual portion pie, rectangular food patty,or other type of food as desired. Chicken nuggets and other food canalso be dispensed with the bulk dispenser previously described. Largeritems of food can span across portions of both elongated spiral flights348 and 350 as illustrated with respect to food item F3, which may be alarger food item, such as a chicken patty, or other type of food articleas desired. Spiral flights 348 and 350 can be of a desired radialdiameter so that the food piece or pieces that are to be contained anddispensed in magazine food dispenser 206 can be accommodated asillustrated in FIG. 8. Each spiral can contain a food piece so that asillustrated in FIG. 7, the illustrated spirals of spiral flights 348 and350 could each accommodate twelve food pieces such as food pieces F1 orF2 for a total of twenty-four food pieces or twelve food pieces such asfood piece F3 of FIG. 8. As will be appreciated, spiral flights having agreater or lesser number of flights can be used if desired to hold agreater or lesser number of food pieces, respectively.

A suitable home position sensor 362′ can be utilized to indicate a homeor start position of each of spiral flights 348 and 350. As illustratedin FIG. 7, a pair of position indicating sensors 362′ and 364′ areutilized and mounted on drive wheel 344 180° apart for more preciselocating of the position of spiral flights 348 and 350. Sensors 362′ and364′ can be proximity sensors that align with corresponding sensorpickups on the respective drive gear or motor for magazine fooddispenser 206 (not shown).

Preferably, spiral flights 348 and 350 are offset by one rotation sothat a single food item such as food item F1 or F2 in FIG. 8 will bedispensed from one of either spiral flight 348 or 350 for each one-halfrotation of spiral flights 348 and 350.

Food dispensing devices 1200 and 1201 may incorporate magazinedispensers such as magazine dispensers 280-308 as previously described.Thus, dispensing device 1200 has a one-by-five array of magazinedispensers, such as magazine dispenser 206 and dispensing device 1201incorporates magazine dispensers 280-308 as previously described fordispensing device 201. Food dispensing devices 1200 and 1201 utilize theconveyor system and food dump mechanism as previously described withrespect to dispensing device 1200.

Preferably, food dispensing devices 200 and 1200 and food dispensingdevices 201 and 1201 are constructed in modular form, an example ofwhich is illustrated in FIGS. 1 and 74 and 2 and 75, respectively.Wheels 368 can be provided to permit cabinets 202, 402 and 602 to besuitably transported across a relatively flat surface, such as arestaurant work area floor.

In accordance with another embodiment of the invention for dispensingmodules 200 and 1200, a magazine dispenser, such as magazine fooddispenser 1206 can be oriented horizontally instead of vertically. Sucha horizontally oriented magazine dispenser can be configured todischarge food items onto an inclined chute contained within the freezercompartment or cavity of dispenser 200 or 1200 (for example cavity 272of device 200) to receive dispensed food items, which chute ispositioned with a discharge end oriented to deposit the food itemsdirectly into secondary container 210 of dispensing device 200 orsecondary container 1210 of dispensing device 1200. Thus, the vibratingconveyor need not be used. The chute may be constructed in any suitableconfiguration, such as, for example, as non-limiting examples, chute498, 1603 or 1554, as illustrated in FIGS. 12, 74 and 85, respectively.In addition, a single spiral flight, such as spiral flight 348, may beused in the horizontal orientation instead of two spiral flights.

An example of the foregoing embodiment is illustrated in FIGS. 77C and77D. As illustrated therein, a magazine dispensing device 1300 isprovided for the dispensing of individual food items, and is orientedhorizontally, forming part of food dispensing module 1302. Food itemsare conveyed by a single spiral conveyor 1304 for each spiral magazine1306 a-c in the direction of arrow SS. Each spiral magazine 1306 a-c isdriven by a suitable motor 1308 or other suitable drive mechanism. Aftera food item is dispensed from one of spiral magazines 1306 a-c, the fooditem falls in the direction of arrow TT and onto inclined chute 1310.The food item then travels down chute 1310 in the direction of arrow UUand into secondary container 1312, which is similar to secondarycontainer 1210, except rear wall 1314 is slightly inclined. The otherindicated elements are similar to dispensing module 1210 or otherelements previously described, as indicated by the reference numeralstherein. Thus, no vibrating conveyor is used in this embodiment for thedispensing of food items from the spiral conveyor, as the food itemstravel to secondary container 1312 by gravity after being dispensed fromone of spiral magazines 1306 a-c.

In addition, a suitable sensor (not shown) may be utilized to sense orcount the number of food articles being dispensed from the spiral flightor flights. The sensor can be any suitable type including, asnon-limiting examples, either an ultrasonic or an optical sensor, whichare well known in the art, or by weighing, such as a load cell.

Food Frying Device

Referring to the Figures generally, and in particular to FIGS. 1-2 and11-24, there is illustrated fry device 400 and various components andalternative components thereof in accordance with the invention.

In one embodiment, fry device 400 includes cabinet 402, four fry wheels404, 410, 412 and 414, four fry vats 406, 416, 418 and 420, four drivemechanisms 408, one for each of fry wheels 404, 410, 412 and 414. Eachfry vat 406, 416, 418 and 420 is dimensioned to contain a desired volumeof a suitable cooking oil. Each fry vat 406, 416, 418 and 420 isdedicated to one of fry wheels 404, 410, 412 and 414, respectively.

In operation in the preferred embodiment, fry device 400 is positionedto receive the food dispensed from a food dispensing device, such asfood dispensing device 200 and food dispensing device 201. Consequently,it is advantageous to position fry device 400 adjacent food dispensingdevice 200 or 201 as illustrated in FIGS. 1 and 2, respectively. Asuitable control panel 456 can be provided and located in a suitablelocation, such as on the side of cabinet 402. In the illustratedembodiment, control panel 456 contains a separate display for each offry wheels 404, 410, 412 and 414 referred to by reference numerals 456a-d, respectively. Control panels and displays 456 a-d can includeinformation such as set cycle time, oil temperature, oil level as wellas controls to adjust cycle time and oil temperature, for example.

Referring to FIG. 13, there is illustrated fry wheel 410. Fry wheel 410includes two opposed circular spaced apart circular disks 458 a and 458b. Disks 458 a and 458 b can include a plurality of apertures 460 asdesired to reduce wheel weight and to provide circulation of cooking oiland to permit passage of water vapor therethrough, such as during fryingfood products, for example. A fry wheel axle 462 is provided to whichdisks 458 a and 458 b are mounted. Axle 462 is suitably mounted,typically and preferably for rotation with respect to fry vat 406 at alocation above the normal level of cooking oil or range of levels ofcooking oil that will be encountered in fry vat 406 during operation.

In one embodiment, outer peripheral edge 464 of each of disks 458 a and458 b include a plurality of teeth 466.

Teeth 466 can be utilized to drive fry wheel 410 in a manner ashereinafter described. Referring to FIGS. 14-16, there is illustrated insectional view of disk 458 a of fry wheel 410, a portion of which islocated within fry vat 406. A drive wheel 468 is associated in operativeposition relative to teeth 466 located on outer peripheral edge 464 ofdisk 458 a. Drive wheel 468 can be formed from a disk of material of asuitable thickness having a circumferential groove 470 therein.Circumferential groove 470 is typically at least or slightly greaterthan the thickness of disk 458 a in the area where drive wheel 468 anddisk 458 a are juxtaposed as illustrated in FIGS. 14 and 15. A series ofspaced apart pins 472 extend across circumferential groove 470 and areradially arrayed and spaced from the center of drive wheel 468. Drivewheel 468 includes a central aperture 474 through which a drive axle 476can be mounted. In operation, drive wheel 468 is rotated by drive axle476 with drive wheel 468 being positioned a fixed distance from disk 458a so that pins 472 mesh with teeth 466 when rotated as illustrated inFIG. 14 thereby causing rotation of disk 458 a and consequently frywheel 410 in a direction of rotation opposite to the rotation of drivewheel 468, as indicated by arrows K and L of FIG. 14.

It is to be understood that any suitable drive wheel and drivearrangement can be utilized. For example, in place of drive wheel 468with pins 472, a drive arrangement could be utilized in which a drivegear is utilized to mesh with a corresponding gear located around theperiphery of disk 458 a and/or 458 b, for example. Alternatively, afriction drive system could be utilized in which a friction drive wheelwould contact the edge of one or both of circular disks 458 which couldbe of a design having no teeth therealong, such as illustrated inalternative embodiment wheels 479 and 481 described hereafter. Since thewheel will have cooking oil thereon, the coefficient of friction betweenthe drive wheel and fry wheel will be decreased. Care should be taken toassure that when using a friction drive, sufficient pressure ismaintained between the driving wheel and the fry wheel.

Referring to FIG. 16, there is illustrated a drive mechanism for drivingdrive wheel 468. The drive mechanism includes an electric motor 478, agear reduction drive 480, an output shaft 482, a drive pulley wheel 484,a driven pulley wheel 486 and a drive belt 488 extending around drivepulley wheel 484 and driven pulley wheel 486 to drive axle 476 whichthereby drives drive wheel 468 since the end 476 a of axle 476 is fixedin aperture 474 with respect to drive wheel 468. A shear pin 490 can belocated in a shear pin aperture 492 of drive wheel 468 to retain axle476 in a fixed position relative to drive wheel 468. Axle 476 issuitably contained within an axle journal 494 which, in turn, is mountedto frame 496 to permit movement of axle 476 relative to axle journal 494and frame 496. Similarly, motor 478 and gear reduction drive 480 aresuitably mounted to frame 496. If desired, motor 478 may be a steppermotor.

Typically, it is important that the fry wheel is rotated in periodicincrements for a compartment to be aligned with a respective dischargeslide 498 of fry device 400 or other slide, ramp or discharge locationafter a periodic rotation. Typically, the leading edge 500 of acompartment bottom, such as compartment bottom 432′ of compartment 432as shown in FIG. 13 is aligned with the upper edge of fry vat 406 or thetop edge of discharge chute 498 associated therewith to allow thecontents of compartment 432 to be discharged therefrom. As illustratedin FIG. 13, the contents of compartment 432 have already been dischargedfrom fry wheel 410. This is particularly important where incrementalrotation of fry wheel 410 is utilized as opposed to a continuouslymoving fry wheel. Thus, for incremental rotation it is desirable forleading edge 500 of compartment 432 to be aligned with discharge 498 orthe upper edge 406′ of fry vat 406. In order to accomplish this, astepper motor can be utilized to drive fry wheel 410. Alternatively, orin addition, the position of the baskets can be sensed and theirposition adjusted accordingly to assure that all baskets are in thecorrect position for loading and discharge during operation. Also,utilizing location sensors allows use of a simple DC or AC motor, asopposed to a stepper or servo motor. Any suitable sensor can be utilizedin conjunction with a control system to control operation of the frywheel drive motor. Suitable sensors include proximity, magnetic reed,Hall Effect, photoelectric and capacitive sensors. Such sensors are wellknown in the art and consequently a detailed description of thosesensors is not included herein.

In accordance with another aspect of the invention, it should beunderstood that the height of cooking oil in one of fry vats 406,416,418 and 420, such as the level of cooking oil indicated by referenceletter H in FIG. 13 in fry vat 406 will increase or decrease dependingupon the amount of food that is submerged underneath the surface ofcooking oil contained in fry vat 406. Thus, as illustrated in FIG. 13,compartments 424, 426, 428 and 430 each have a charge of food, in thiscase French fries 455 contained therein. Each compartment containsapproximately one pound of French fries 455. Consequently, there areabout four pounds of French fries that are beneath the surface level Hof cooking oil contained in fry vat 406. This quantity of submerged foodraises the level H of cooking oil in fry vat 406. This increase in thelevel of cooking oil can cause the food to be submerged and thereforecooked for a longer of period of time in the cooking oil. For example,contrast the level of cooking oil depicted in FIG. 13 with the level ofcooking oil depicted in FIG. 20 in which a charge of French fries 455 iscontained only within compartment 426. This results in a substantiallyreduced level of cooking oil H′ as indicated in FIG. 20. Thus, thecontrol system for fry device 400 can be adjusted to take into accountfor different levels of cooking oil which can be sensed by a suitablesensor as is known by those skilled in the art (not shown). Whererotation of fry wheel 410 is done incrementally after a period of timeelapses, the period between incremental rotations can be increased ordecreased as desired based on the level of cooking oil present in fryvat 406. For example, in the situation illustrated in FIG. 13, theduration between incremental rotation of fry wheel 410 could bedecreased compared to the situation depicted in FIG. 20 where the levelH′ of cooking oil is significantly lower than the level H of cooking oilin FIG. 13. This assumes that the temperature of cooking oil in each ofthe situations depicted in FIGS. 13 and 20 is substantially the same.Similarly, if a constant rotation fry wheel operation is utilized, suchas where fry wheel 410 would rotate constantly, the rotational speedcould be increased to handle the situation depicted in FIG. 13 comparedto the speed of the wheel that would be utilized for the situation inFIG. 20, where the level H′ of cooking oil in FIG. 20 is significantlyless than the level H of cooking oil in FIG. 13.

Referring to FIGS. 13 and 20, frying device 400 can also include a frywheel follower or “fry wheel liner” 502 which is supported by a frywheel follower support 504. Fry wheel follower 502 is a curvedperforated circular segment having a width approximately equal to thewidth of fry wheel 410. Fry wheel follower 502 is supported by a pair offry wheel follower supports 504 that are spaced apart and connected bylateral supports 506. Fry wheel follower 502 prevents food pieces thatare larger than the perforations in fry wheel follower 502 from fallingfrom fry wheel compartments 422-436 during operation. Preferably, theperforations in fry wheel follower 502 are composed of circular holeshaving a diameter of about 0.187 inches that are in staggered rowshaving a center-to-center hole distance of about 0.312 inches. Fry vat406 includes a suitable heating element 505, illustrated in FIGS. 13, 20and 21.

Referring to FIGS. 17-19 there is illustrated a curved compartmentforming member 438 which is composed of two opposed sidewalls 508 a and508 b that are interconnected by a perforated curved compartment formingmember 510 that forms compartment bottom 510 a and compartment top 510b. Preferably, a wiper 512 is suitably mounted to compartment formingmember 510.

A plurality of compartment forming members 438 are mounted together infry wheel 410 to provide a plurality of adjacent peripheral foodcompartments 422-436 as illustrated in FIG. 13. As illustrated in FIG.13, the top of one compartment forming member 510 abuts the bottom ofadjacent compartment forming member 510. Thus, advantageously, afastening member 514, which can be a rivet, for example, that secureswiper 512 to compartment bottom 510 a of one compartment forming member510 will also pass through the compartment top 510 b of the adjacentcompartment forming member 510. Preferably, wiper 512 has a plurality oftransversely extending grooves 516 a-f that permit drainage of cookingoil therethrough as wiper 512 exits the cooking oil in fry vat 406, forexample.

Referring to FIG. 17, opposed sidewalls 508 a,b and compartment formingmember 510 are perforated to permit the flow of cooking oil therethroughthereby promoting good heat transfer between the cooking oil containedin fry vat 406 and food contained in one of compartments 422-436 whenimmersed in cooking oil. A suitable hole size is about 0.156 inchesspaced center-to-center about 0.250 inches. Wiper 512 also ensures thatclose contact is maintained between the interface of fry wheel follower502 and the top and bottom ends of each food compartment 422-436 whichin each case will be bounded by one of wipers 512. Any suitable materialcan be used for wiper 512 such as rubber or Teflon®, for example. Amagnet may be incorporated into wiper 512 for use in conjunction with areed switch to determine compartment location. Alternatively, a ferrousedge on compartment bottom 510, for example, for use with a modifiedreed switch that is fitted with a magnet.

As an alternative construction, compartments 422-436 could beconstructed from compartment forming members 510 without opposedsidewalls 508 a and 508 b, in which case the compartment sidewalls couldbe formed from opposed circular disks 458 a and 458 b. In addition, itshould be appreciated by one skilled in the art that any desiredcompartment shape can be utilized in accordance with the invention aslong as the food can be loaded into the compartment, kept within thecompartment during immersion in the cooking oil and which compartmentshape discharges the food from the fry wheel.

Referring to FIGS. 21 and 22, there are illustrated further aspects offry device 400. FIG. 21 is a sectional view along line 21-21 of FIG. 20.FIG. 21 illustrates the elements previously described and in additionshows the interface of adjacent fry vats 406 and 420 and in enlargedform in FIG. 22. Disposed between fry vats 406 and 420 is a bankingstrip 518 that bridges the gap between fry vats 406 and 420. Bankingstrip 518 can be in a shape as desired and in the illustrated embodimentis a generally inverted V-shaped strip that spans the gap between fryvats 406 and 420. Banking strip 518 prevents any material that isdischarged between fry wheels 410 and 412 from falling between fry vats406 and 420 and causing such material to fall into one of fry vats 406and 420.

Referring to FIGS. 23 and 24, there are illustrated alternateembodiments of a fry wheel for use in accordance with the invention. Itis to be understood that the fry wheel is capable of numerous changesand rearrangements, and the fry wheel, as well as other components andembodiments of the present invention, is not intended to be limited tothe specific embodiments described herein.

Referring to FIGS. 23 and 24, there are illustrated wire form wheels 479and 481. Each of wheels 479 and 481 has a rim 520 and 522, respectively,constructed of tubing, which can be smooth tubing. Such a wheel could bedriven by a friction wheel, if desired. In each of wheels 479 and 481 aplurality of individual tubular spokes 524 extend from each rim to acorresponding hub assembly 526. An axle 528 connects hubs 526 togetherin each of wheels 479 and 481. Wheel 479 includes a slotted member 530that bridges each pair of spokes 524. Each slotted member 530 includes acentrally disposed slot 532 and a pair of tabs 534 on either side ofslot 532. A plurality of fry baskets 536, one for each slotted member530 or pair of spokes 524 is mounted in a snap-lock relationship to eachslotted member 530. Fry baskets 536 have perforated sides and aperforated bottom and top and can be of a similar configuration aspreviously described with respect to fry wheel 410. Each basket 536 canhave a spring tab member 538 that interlocks with slotted member 530 tosecure fry basket 536 to fry wheel 479 resulting in a finished fry wheel481 as shown in FIG. 24. It is to be understood that the embodimentillustrated in FIGS. 23 and 24 is not limited to snap-in baskets andthat other baskets can be used with the wheel arrangement depicted inFIG. 23 with or without slotted members 530. For example, baskets couldbe welded or otherwise affixed to rim 520 and spokes 524. Each of frybaskets 536 includes perforations 540 on the sides, top and bottomthereof, such as previously described with respect to compartmentforming member 438.

Referring to FIG. 24, there is illustrated an alternative drivemechanism 535 to rotate fry wheel 481. Drive mechanism 535 includes amotor 537, a shaft 539 and drive rollers 541 and structure for supplyinga force in the direction of arrow FW. Drive rollers 541 are mounted onshaft 539 which can be rotated by motor 537 to cause rollers 541, eachaligned with one of rims 522, to rotate, thereby rotating fry wheel 481.A force FW is supplied in the direction of arrow FW to ensure thatrollers 541 impart a sufficient tractive force to cause rotation of frywheel 481. Force FW can be supplied by any suitable structure, includinga spring, a weight or an electromagnet, for example. For example, motor537, shaft 539 and rollers 541 could be mounted on a platform (notshown) that is movable in the direction of arrow FW and a force could beapplied to urge the platform in the direction of arrow FW to ensureproper traction of rollers 541. Rollers 541 may be constructed of anysuitable material, including rubber, for example. Motor 537 can becontrolled by subcontrol system 116, for example.

Fry wheel 410 can be rotated as desired so that food deposited in one ofcompartments 422-436 travels through and out of the cooking oil 454until that compartment reaches a discharge location. Thus, in theembodiment illustrated in FIGS. 13 and 20, the rotation is in aclockwise direction as indicated by arrow K in FIG. 13 and arrow K inFIG. 20. The rotation of fry wheel 410 can be either continuous orperiodic. In a periodic rotation, the rotation will typically beincremental, that is, the wheel is rotated to some degree and thenstops. Thereafter, after a set period of time, the wheel undergoesanother periodic rotation. This process continues as each fry basket isrotated through and out of the cooking oil vat and to the dischargelocation. Preferably, each periodic rotation consists of a rotation of360° divided by the number of compartments present in the fry wheel orsome fraction of that periodic rotation increment so that the positionof the wheel can be known without the use of sensors. However, the useof a sensor or sensors to be able to monitor wheel position can also beused either as the primary way of controlling wheel position or as abackup. Also, use of a sensor to determine wheel position allows use ofa standard AC or DC motor. Suitable control of wheel 410 can beaccomplished by fry control 116, for example.

In accordance with the present invention, a basket shaking simulationcan be achieved. Basket shaking simulation can be performed by arelatively slight back and forth rotation of the fry wheel, such as frywheel 410. Thus, the drive mechanism is activated to rotate the frywheel clockwise and counterclockwise through a relatively small degreeof angular rotation to simulate shaking of a fry basket during frying.The back and forth rotation can occur relatively rapidly and typicallythe degree of angular rotation will be in the range of from about 2 toabout 20 degrees. In addition, the periodic rotation in one directionmay be of a larger angle of rotation than the rotation in the otherdirection.

Preferably, the degree of rotation during simulated basket shaking willbe monitored, particularly where the rotation in one direction isgreater than the rotation in the other direction so that the position ofeach basket relative to the discharge location can be monitored by thecontrol system to ensure proper discharge of food from foodcompartments.

Referring to FIG. 64, there is illustrated in partially schematic viewfry device 400 along with portions of food dispensing device 200 andfood packaging device 600. As illustrated in FIG. 64 a hood system 546is provided. Hood system 546 includes a hood structure 548, a filter 542and a drip pan 544.

A suitable air blower (not shown) can be provided to cause air flow tomove within hood system 546 generally in the direction of arrows A1, A2and A3. Filter 542 thus filters particulate matter in air flow A1 thatpasses through filter 542. Drip pan 544 catches any matter that dripsfrom filter 542 that is located above drip pan 544. Preferably, hoodsystem 546 substantially completely encloses the area above fry device400 to reduce waste discharge into the operating environment ofautomated food processing system 100.

Fry module 1400 is similar to fry module 400 previously described andcan be operated and controlled as described with respect to fry module400. In addition, control system 1116 for fry module 1400 is similar tocontrol system 116 previously described.

FIG. 85 illustrates a fragmentary perspective view of a portion of frymodule 1400, which includes a foam deck 1550 and an overflow passageway1552. Foam deck 1550 is located below food inlet slide or chute 1554 tofry module 1400, which is disposed to receive food items from dispensingmodule 1200 or 200, for example, and into one of compartments 422-436 offry wheel 410. Thus, foam deck 1550 is located above the normaloperating level of frying oil in fry vat 406 and is on the food inletside of fry module 1400 adjacent inlet slide or chute 1554. Overflowpassageway 1552 is an elongated slot that can be routed to a drain orwaste container as indicated by arrow WW. Typically, when a quantity offood, particularly frozen, is placed in a fry vat, foaming occurs in thehot oil that contains water. Some of the foam is collected on the foamdeck and drains through the overflow passageway, thereby eliminatingsome of the foam and water that results from the initial charging offood to fry module 1400.

Food Packaging Device

Referring to the Figures generally, and in particular to FIGS. 1, 25-50,74, 76 and 86-91, there are illustrated various embodiments of foodpackaging devices and elements thereof in accordance with the invention.

In one embodiment, food packaging device 600 is illustrated or partiallyillustrated and elements useful in connection with food packaging device600 are illustrated in FIGS. 1 and 25-50. Food packaging device 600includes a cabinet 602 having a countertop surface 636. Food packagingdevice 600 can be advantageously constructed in modular form so that itcan be operated together with previously described food dispensingdevice 200 and fry device 400 and alternatively operated separately fromboth or either of those devices.

Food packaging device 600 in the illustrated embodiment includes a foodinlet chute 604, rotatable food dispensing member 606, food dispensingchute mechanism 608, automated container handling system 610,container-receiving receptacle 612, overflow food collection member 613,conveyor system 614, waste chute 615, food seasoning system 616 andraceway 620.

In the illustrated embodiment, food packaging device 600 includes acontainer storage device for containing cartons or containers of varioussizes. During operation of packaging device 600, the device selects acontainer of a desired size from container storage magazine 638, erectsthe container into an erected form that is unerected while contained instorage magazine 638 and then positions the erected container to receivefood dispensed from food dispensing chute mechanism 608. After receivingfood from food dispensing chute mechanism 608, automated containerhandling system 610 is capable of moving the filled or partially filledcontainer to container receiving receptacle 612 which is transported viaconveyor system 614 to a desired location for subsequent pickup of thecontainer by a human operator, for example.

In the embodiment illustrated in FIGS. 25-29, food packaging device 600includes food overflow collection member 613 to collect food dispensedby food dispensing chute mechanism 608 that is not deposited into acontainer. In the illustrated embodiment, overflow food collectionmember 613 is a rotatable wheel as hereinafter described in detail.Overflow food collection member 613 functions to collect food dispensedby food dispensing chute mechanism 608 that is not received in acontainer and to recycle that food into food dispensing chute mechanism608 for subsequent dispensing to a container. This permits fooddispensed by food dispensing chute mechanism 608 but not deposited in acontainer to be promptly recycled to the dispensing chute in a first-in,first-out manner, so that overflow food is promptly recycled anddispensed to a container.

Referring to FIGS. 26-28, there is illustrated food packaging device 600in which inlet chute 604 is positioned to receive food, in this caseFrench fries, from food dispensing lanes 234, 236 and 238 of dispensingdevice 200, which food has been subsequently fried after dispensing infry wheels 410, 412 and 414 of fry device 400. After frying in any ofwheels 410, 412 and 414 of fry device 400, food dispensed therefromenters inlet chute 604, as illustrated in FIGS. 3 and 28, for example.In inlet chute 604 the food travels downwardly along chute 604 and intorotatable food dispensing member 606 in the direction of arrow M of FIG.28 and arrow E of FIG. 3. Inlet chute 604 can be configured as desiredand may be configured to accept the product from any one or all of frywheels 404, 410, 412 and 414. In FIGS. 25-27, a holding area 607receives product from fry wheel 404 for manual packaging. A manual orautomated diverter bar 605 can optionally be provided as shown in FIG.27 to divert French fries from device 600 to permit filling unsalted fryorders. Bar 605 can be moved between open and closed positions asindicated by arrow Z, such as by a cylinder (not shown).

Rotatable food dispensing member 606 in the illustrated embodiment is adispensing wheel that is mounted for rotation in dispensing device 600.Dispensing member 606 has a plurality of food containing compartments640 that are arrayed around the periphery of rotatable food dispensingmember 606. Each of compartments 640 is divided from another compartmentby a compartment wall 642. Preferably, each compartment wall 642 is notnormal to peripheral edge 644 of rotatable food dispensing member 606but at a slight angle such as, for example, as illustrated in FIG. 29and FIG. 61.

Wheel 606 includes a pair of opposed rim portions 646 a and 646 b and acircular ring portion 648 that interconnects opposed rims 646 a and 646b. Circular ring 648 is disposed close to the peripheral edges of rims646 a and 646 b and defines peripheral edge 644. Preferably, circularring 648 is constructed of a perforated metal material so that circularrims 646 a and 646 b have perforations 650 therethrough as illustratedin FIG. 28, for example.

In accordance with the illustrated embodiment, rotatable dispensingmember 606 is configured as a rotatable wheel although other embodimentsare within the scope of the invention. For example, a rotatabledispensing member in accordance with the invention could be a portion ofa wheel, such as a semicircular or other configuration.

In the illustrated embodiment, rotatable food dispensing member 606 isrotated by a drive mechanism 652. Drive mechanism 652 consists of amotor 654 that drives a drive wheel 656. Drive mechanism 652 iscontrolled by a suitable control mechanism to cause rotation of drivewheel 656 and hence moves rotatable food dispensing member 606 in adesired direction and at a desired rate of speed. Drive wheel 656 can bea pressure roller or alternatively can be a drive wheel like or similarto drive wheel 468 previously described with respect to FIG. 14.Rotatable food dispensing member 606 can be driven via one or both ofopposed rims 646 a and 646 b. Alternatively, and as illustrated in FIG.28, rotatable food dispensing member 606 is driven through a drive rim658. Each of rotatable food dispensing members 606 and overflow foodcollection member 613 rest on spaced apart rollers 660 and 662. Each ofrollers 660 and 662 are constructed to bear the weight of rotatable fooddispensing member 606 and overflow food collection member 613 and have alength that spans both. Alternatively, separate rollers or some othersupporting structure could be used to support rotatable food dispensingmember 606 and overflow food collection member 613. An inner curvedfender or baffle member 664 as illustrated in FIG. 29 is provided toensure that food contained in compartment 640 of rotatable fooddispensing member 606 does not prematurely discharge. Preferably, fender664 follows the inner curvature of rotatable food dispensing member 606and has perforations 666, which can be similar to perforations 650 ofcircular ring 648. Fender 664 is suitably mounted so that it isstationary relative to rotatable food dispensing member 606. A similarfender could also be provided for overflow food collection member 613,if desired (not shown).

Referring to FIG. 61, there is illustrated an elevation view of aportion of rotatable food dispensing member 606 which is typicallyrotated in the direction of arrow Y when viewed from the front of foodpackaging device 600. Fender 664 prevents food, in this case Frenchfries FF, from falling from compartments 640 prematurely.

Overflow food collection member 613 is configured to collect fooddeposited from food dispensing chute mechanism 608 that is intended tobe received into container 611 when held in position to receive foodfrom food dispensing chute mechanism 608 which food does not stay incontainer 611. This can occur since oftentimes it is desirable tooverfill container 611 so that food is mounded up above the top surfaceof container 611. Also, for food such as French fries, such foodmaterial fills container 611 somewhat randomly and it is typical forFrench fries to dangle over the sides of container 611. In theillustrated embodiment, overflow food collection member 613 isconfigured in a manner similar to rotatable food dispensing member 606previously described. Thus, food collection member 613 includes opposedrims 668 a and 668 b and circular ring 670 having perforations 672.Circular ring 670 connects opposed rims 668 a and 668 b in a manner aspreviously described with respect to member 606. In addition, foodcollection member 613 has a plurality of inner compartments that aresimilar in construction to compartment 640 previously described withrespect to member 606. Member 613 also has a drive rim 674 and is drivenby a drive mechanism 676 that is similar to drive mechanism 652previously described including a drive wheel 676′ and a motor 678. Drivemechanism 676 is configured to rotate food collection member 613 ineither a clockwise or counterclockwise direction as hereinafterdescribed in more detail.

Food collection member 613 also includes a plurality of compartmentwalls 680 that are similar to compartment walls 642 previously describedwith respect to rotatable food dispensing member 606, providing aplurality of food containing compartments 682.

Each of food dispensing member 606 and food collection member 613 hasbottom portions that are disposed through an opening 684 in countertopsurface 636 of cabinet 602. The construction of the illustratedembodiment permits food dispensing member 606 and overflow foodcollection member 613 to be readily removed from food packaging device600 such as for cleaning and/or repair.

A heating system as described can be incorporated into food packagingdevice 600 to supply heat to food contained therein. For example, aheating system 681 can be provided, which is illustrated in FIG. 29.Heating system 681 includes a heating device 683 having a heatingelement 685, located above dispenser 606 as desired. Heating devices 687and 689 may also be included within dispenser 606 and/or 613 as desired.The heating devices may comprise radiant heaters and can be ceramicheaters, for example. Any suitable type of heating device or system canbe used in accordance with the invention. Heating system 681 can becontrolled by subcontrol system 118, for example. In addition, a heatingdevice can be provided to direct heat to food container pick up location622, if desired to keep food contained thereat warm.

Referring to FIGS. 1, 3, 25-26, 28-29 and 43-44, various aspects of theconfiguration and operation of food dispensing chute mechanism 608 areillustrated and will be described. Food dispensing chute mechanism 608includes an upper chute 686, a lower chute 688, a chute support member690, a connecting link 692, a stop member 694, a rotatable link 696connecting stop member 694 to chute support member 690, a rotatable link698 connecting upper chute 686 to support member 690, a cylinder 700 foroperating food dispensing chute mechanism 608, a load cell 702 forweighing the contents of food contained in food dispensing chutemechanism 608 and a rotatable link 704 connecting cylinder rod 706 toupper chute 686.

Upper chute 686 preferably and as illustrated in the referenced figures,forms part of food dispensing chute mechanism 608, and has an inletlocation 708 for receiving food dispensed from rotatable food dispensingmember 606 and a discharge location 710 for dispensing food contained infood dispensing chute mechanism 608 and into a container, such ascontainer 611 as illustrated in FIG. 43, for example.

Upper chute 686 of food dispensing chute mechanism 608 is positioned toreceive pieces of food from a discharge location 712 of rotatable fooddispensing member 606. Upper chute 686 has a food holding area 714 forholding food received from rotatable food dispensing member 606. Aweighing device is associated with food dispensing chute mechanism 608so that the amount of food contained therein, such as in food holdingarea 714, can be determined. Any suitable device can be utilized todetermine the amount of food contained in food dispensing chutemechanism 608. In the illustrated embodiment, a load cell 702 isprovided to determine the weight of food contained in food dispensingchute mechanism 608 and is illustrated schematically in FIGS. 43 and 44,for example.

FIG. 44 illustrates food dispensing chute mechanism 608 in the upperposition ready to receive food from rotatable food dispensing member606. In that configuration, cylinder 700 is retracted and upper chute686 is generally horizontal. This configuration allows a quantity offood to be dispensed into upper chute 686 and into food holding area 714without being dispensed therefrom. When a sufficient quantity of food isdeposited in upper chute 686, such as French fries FF, as determined byload cell 702 which communicates with the control system of foodpackaging device 600, the food contained therein is ready to bedispensed. Typically, the amount of food contained in chute 686 will besufficient to adequately fill container 611. Since container 611 is of aknown size, rotatable food dispensing member 606 can be operated tosupply food to chute 686 until a desired quantity is contained thereinfor dispensing to container 611.

To dispense food from food dispensing chute mechanism 608, cylinder 700is activated to extend cylinder rod 706 upwardly thereby causing upperchute 686 to drop. Since lower chute 688 is connected to upper chute 686via connecting link 692, lower chute 688 also drops to the dischargeposition as illustrated in FIG. 43 which movement is indicated by arrowS. Stop 694 which is connected to lower chute 688 and pivotally mountedvia rotatable link 696 to chute support member 690, engages chutesupport member 690 as illustrated in FIG. 43 and prevents furtherdownward movement of upper chute 686 and lower chute 688. In addition,stop member 694 engaging chute support member 690 defines the lowermostposition of upper chute 686 and lower chute 688 which is also thedispensing position of food dispensing chute mechanism 608, asillustrated in FIG. 43. This position also provides discharge location710 of dispensing chute mechanism 608.

Referring to FIGS. 25-28, there is illustrated container storagemagazine 638, which can form part of food packaging device 600.Container storage magazine 638 is configured to store a plurality ofdifferent sized food containers in an unerected form. Typically,container storage magazine 638 will be configured to hold a variety ofdifferent sized containers. In the illustrated embodiment, containerstorage magazine 638 can contain four different sizes of French frycontainers or cartons. Container storage magazine 638 includes a base716 that is suitably mounted with mounting structure 718 to cabinet 602.Preferably, mounting structure 718 permits container storage magazine638 to be readily removed to permit access to rotatable food dispensingmember 606 and overflow food collection member 613.

Base 716 typically can be in the form of a base plate and includes fourapertures 720, 722, 724 and 726, each of said apertures corresponding tothe profile of a different size collapsed carton. Apertures 720, 722,724 and 726 are dimensioned to be able to retain a stack of cartons in acollapsed or unerected condition as illustrated in FIG. 25 in which aplurality of unerected cartons 728 are stacked therein.

Each aperture 720, 722, 724 and 726 and base 716 has associatedtherewith a plurality of guide members 730-760. In the illustratedembodiment, guides 730-760 are in the form of post or tubular-typemembers. Each set of four guide members is associated with a specificone of apertures 720, 722, 724 and 726 to define and permit stacking ofa plurality of unerected French fry cartons or containers that generallycorrespond in size to the size of apertures 720, 722, 724 and 726,respectively. It is to be understood that other arrangements to define acontainer stack can be utilized in accordance with the invention. Forexample, in place of guides 730-760 other structure could be utilized,such as upstanding walls or partial walls or other types of guides.

Container storage magazine 638 may also include a suitable removablecover (not shown) to enclose base 716 and the volume defined overapertures 720-726 by guides 730-760.

Container storage magazine 638 is preferably positioned to permit readyaccess to the bottom of each container stack through the bottom of eachof apertures 720-726 by automated container handling system 610, whichis hereinafter described in detail.

Food packaging device 600 includes automated container handling system610. Automated container handling system 610 is capable of retrieving anunerected container through any of apertures 720, 722, 724 and 726 ofunerected container storage magazine 638, erecting the unerected carton,holding the erected carton in position at discharge location 710 of fooddispensing chute mechanism 608 and depositing the filled container ontoconveyor system 614, which conveyor system 614 subsequently transportsthe filled container to a desired location.

Referring to FIGS. 1, 25, 27-28 and 30-44, there is illustratedautomated container handling system 610 and elements and featuresthereof. Automated container handling system 610 includes a containerretrieving and grasping device 762, a container grasping device 764 anda container bottom urging device 766.

Automated container handling system 610 is controlled by a suitablecontrol system for food packaging device 600.

Container retrieving and grasping device 762 and portions thereof arebest illustrated in FIGS. 30-39. Container retrieving and graspingdevice 762 includes a mast 768, which is mounted to a carriage system770, a movable rack member 772, a pinion 774, a frame 776, a containergrasping member 778 and a linkage assembly 780.

Mast 768 is carried by carriage system 770 which carriage system 770allows for lateral translation of mast 768 and the components associatedtherewith, including movable rack member 772, pinion 774, frame 776,container grasping member 778 and linkage assembly 780. Carriage system770 includes a guide member 782, a worm gear 784, a drive mechanism 786and a carriage follower 788. Carriage follower 788 supports a verticaltranslation mechanism 790 that, in turn, carries mast 768.

Carriage guide 782 is an elongated guide that defines the lateraltranslation movement direction of carriage follower 788 and is securedwithin cabinet 602. Worm gear 784 is disposed parallel to carriage guide782 and when rotated moves carriage follower 788 along carriage guide782.

Worm gear 784 is driven by drive mechanism 786 which can include a drivemotor 792, a drive gear or pulley 794 and a driven gear or pulley 796.Where drive and driven pulleys are used, typically a belt 798 willimpart rotation from one pulley to another.

Drive motor 792 drives driven pulley 796 and causes worm gear 784, whichis mounted for rotation, to be rotated by rotation of driven pulley orgear 796 in either direction. Drive motor 792 can be an AC or DC motoror a stepper or servo motor as desired. Suitable sensors can be employed(not shown) to determine the position of carriage follower 788 whichdetermines the lateral position of container grasping member 778.

Carriage follower 788 is composed of a frame 800 having a guide apertureor slot 802 in which carriage guide 782 is disposed and a threadedaperture or slot 804 in which elongated worm gear 784 is disposed toimpart lateral motion to carriage follower 788 by rotation of worm gear784. Thus, carriage system 770 provides lateral movement in thedirection of arrows Q as shown in FIG. 39. In this manner, carriagefollower 788 and thus mast 768 can be laterally translated as desired.

A suitable opening 806 is located in countertop surface 636 of cabinet602 to permit mast 768 to extend therethrough.

Mast 768 can be raised and lowered in a vertical direction as indicatedby arrow V in FIG. 39.

Mast 768 can be vertically raised and lowered in the directionsindicated by arrow V in FIG. 39 by operation of a drive mechanism 810that forms part of vertical translation mechanism 790. Verticaltranslation mechanism 790 is a vertically extending carriage systemsimilar to that described with respect to carriage system 770 andincludes a drive mechanism 810 which is composed of a motor 812 which iscarried by carriage follower 788, a vertically disposed carriage guide814, a vertically disposed worm gear 816 which is driven in a suitablemanner by motor 812 such as previously described with respect to drivemechanism 786 of carriage system 770, which can be controlled in asimilar manner. Vertical translation mechanism 790 also includes avertical carriage follower 818 having a threaded aperture or slot and aguide aperture or slot (not shown) which vertical carriage follower 818is secured to mast 768.

Mast 768 has mounted thereto frame 776, typically at an upper endthereof. Linkage assembly 780 is secured to frame 776 as well as pinion774 and movable rack member 772.

Movable rack member 772 includes a frame 820 having a guide slot 822vertically disposed therein and a rack 824 which meshes with pinion 774.Movable rack member 772 may also include extra mass in the form of aweight block 826 to help urge movable rack member 772 downwardly whennot restrained.

A pair of guides 828 and 830 are rigidly secured to frame 776 and aredisposed within slot 822 of movable rack 772. A spring 832 can beconnected between an upper end of movable rack member 772 and guide 828or 830 to urge movable rack member 772 to a lower position asillustrated in FIG. 30 compared with the upper position as illustratedin FIGS. 34-37.

In a preferred embodiment, movable rack member 772 includes a stop 834which stop can be vertically adjustable. While stop 834 is located atthe bottom of movable rack member 772 it is to be understood that a stopcould be provided at another location provided that a suitable engagingsurface at a proper location is provided.

Mounted to frame 776 is an axle 836 that is mounted for rotationrelative to frame 776. Axle 836 has pinion gear 774 rigidly securedthereto as well as one end 838 of linkage 780. The other end 840′ oflinkage 780 is securely mounted to frame 776 as illustrated in FIGS.30-37, for example.

Linkage 780 which carries container grasping member 778 is composed of aplurality of links so that container grasping member 778 is movable froma horizontal position as illustrated in FIGS. 30-32 to a verticalposition as illustrated in FIGS. 34-37. When container grasping member778 is in the horizontal position it is utilized to grasp and retrieve adesired size of container from one of the apertures 720, 722, 724 and726 from container storage magazine 638. For this purpose, containergrasping member 778 includes a suction cup device 840 which includes atleast one suction cup 842 and in the illustrated embodiment two suctioncups 842 and 844 arrayed in substantially the same plane for grasping acontainer having a surface to be grasped by both suction cups 842 and844 in the same plane. Suction cup device 840 also includes a vacuumsource 846, a release valve 848 and a suitable vacuum line 850 whichconnects suction cups 842 and 844 to vacuum source 846, as illustratedin FIG. 30, for example. In operation, when suction cups 842 and/or 844engage a container or other member to be grasped, vacuum source 846 isactivated to supply vacuum to suction cups 842 and 844, such as to graspand retain a container from one of apertures 720, 722, 724 and 726 ofcontainer storage magazine 638.

Linkage assembly 780 includes, in the illustrated embodiment, a firstlink 852, a second link 854 and third link 856.

First link 852 is rigidly secured to axle 836 and pinion 774. First link852 is configured in an L-shape with the end of first link 852 oppositethe portion connected to axle 836 pivotally connected to second link 854having one end being pivotally connected to first link 852 via pivotconnection 858.

Second link 854 is connected to third link 856 via a universal jointconnection 860 a location spaced apart from pivot connection 858 asillustrated in, for example, FIGS. 30-37. Suction cups 842 and 844 aremounted to second link 854. An offset member 862 which depends fromsecond link 854 provides a desired offset for universal joint connection860 which connects second link 854 to third link 856.

Third link 856 is, in turn, connected to frame 776 via a universal jointconnection 864 which is at a distance removed from universal jointconnection 860 which connects third link 856 to second link 854. Anoffset member assembly 866 is rigidly secured to frame 776 and includesan angled block 868 and an offset extension 870 to provide the desiredangle and clearance for universal joint 864 and third link 856.

In operation, when movable rack member 772 is moved relative to mast768, such as when stop 834 contacts a surface, such as in theillustrated embodiment, countertop surface 636 as illustrated in FIG.36, continued downward vertical movement of mast 768 causes rack member772 to move upwardly relative to mast 768. This causes rotation ofpinion 774 which meshes with rack 824 mounted to rack member 772.Rotation of pinion 774 in a counter-clockwise direction in FIG. 30causes rotation of first link 852. Such rotation causes downwardmovement of that portion of first link 852 that is pivotally connectedto second link 854 via pivot connection 858. Such movement, in turn,causes second link 854 to pivot upwardly about pivot connection 858 in aclockwise direction as viewed in FIG. 30 to cause suction cups 842 and844 to move to a vertically oriented position as depicted in FIGS. 34-37from the horizontally oriented position depicted in FIGS. 30-33. Inaddition, such movement of first link 852 causes movement in rotation ofthird link 856 and universal joint connection 860 and 864 to theposition indicated in FIGS. 34-37. When container grasping member 778 isin the position indicated in FIGS. 34-37, an unerected container held bysuction cups 842 and/or 844 will be vertically oriented when suctioncups 842 and/or 844 are attached to the container sidewall, asillustrated in FIG. 40, for example.

In a typical operation, container retrieving and grasping device 762will be operated to position suction cups 842 and 844 below a containerto be selected from container storage magazine 638. Mast 768 will beraised by operation of vertical translation mechanism 790 to a desiredheight so that suction cups 842 and 844 engage a container contained atthe bottom of container storage magazine 638. Vacuum source 846 isactivated and mast 768 can be lowered to remove a container from adesired one of apertures 720, 722, 724 and 726 of container storagemagazine 638. Carriage system 770 can be activated to move containerretrieving and grasping device 762 laterally to a desired location. Suchlateral movement can be controlled by properly positioned sensors 872,874, 876, 878 and 880, for example. For example, sensor 872 can definethe position to retrieve a container from aperture 720, sensor 876 toretrieve a container from aperture 722, sensor 878 to retrieve acontainer from aperture 724 and sensor 880 to retrieve from aperture726. Sensor 874 can be positioned to define the proper location ofcontainer grasping member 778 to erect the container that has beenretrieved from one of apertures 720, 722, 724 or 726 of containerstorage magazine 638, as hereafter described. After erecting thecontainer, the vacuum applied to suction cups 842 and 844 is released byoperation of release valve 848 which permits suction cups 842 and 844 todisengage and release the container that had been grasped. Mast 768 canthen be raised causing stop 834 to be removed from countertop surface636 and by action of weight 826 and operationally spring 832, causingrack member 772 to move downwardly relative to mast 768 thereby rotatingpinion gear 774 clockwise relative to the position shown in FIG. 34,thereby moving linkage assembly 780 to cause movement of containergrasping member 778 from the position illustrated in FIGS. 34-37 to theposition indicated in FIGS. 30-33, where container grasping member 778is in position to retrieve a desired carton from container storagemagazine 638 in a manner previously described, which includes lateraltranslation of container grasping member 778 by carriage system 770.

It is to be understood that any suitable automated device or system forretrieving, grasping and moving a container to a desired location asdesired herein can be utilized in accordance with various aspects of thepresent invention. Thus, various aspects of the present invention arenot limited by the particular embodiment of container retrieving andgrasping device 762 and components thereof described herein. Forexample, an automated or robotic arm could be utilized to select, graspand retrieve erected or unerected containers from a source as desiredand then erect the carton or container in a suitable manner, followed byholding the erected container at discharge location 710 and afterfilling placing the filled container, such as container 611 onto asuitable conveyor to move the filled container to a desired location.

Container grasping device 764 of container retrieving and graspingdevice 762 will now be described, and in particular with reference toFIGS. 38 and 40-44.

Container grasping device 764 includes a rotatable and verticallytranslatable mast 884. Mast 884 can be rotated as illustrated by arrow Pin FIG. 38 and vertically translated up and down as indicated by arrow Oalso in FIG. 38. Mast 884 is connected to a shaft 886 via a slot and keyarrangement between mast 884 and shaft 886 permitting mast 884 to berotated by shaft 886 which, in turn, can be rotated by a stepper motor890 or other suitable motor or device to rotate shaft 886 a desireddegree. Motor 890 drives a drive pulley or gear 892 which, in turn,drives a driven pulley or gear 894. In the case where pulleys areutilized, a belt 896 is used to transmit rotation from pulley 892 topulley 894. Motor 890 can be a stepper motor or a servo motor asdesired. Alternatively, an AC or DC motor can be utilized provided thata suitable control is provided so that the orientation of mast 884 canbe determined. A carriage system 898 is utilized to provide the desiredvertical movement of mast 884 in up and down directions. Carriage system898 is similar to carriage system 770 previously described and includesa carriage guide 900, a worm gear 902, a carriage follower 904, a drivemechanism 906 which includes a motor 908 (which can be a servo motor oran AC or DC motor) suitably controlled to drive worm gear 902. Carriagefollower 904 includes a threaded aperture or slot 910 which communicateswith worm gear 902 and a threaded aperture or slot 912 in which guide900 is disposed. A carriage follower interface 914 connects carriagefollower 904 to mast 884 and permits shaft 886 to rotate with respect tocarriage follower interface 914. Thus, in operation, rotation of motor908 rotates worm gear 902 thereby translating carriage follower 904 upor down depending on the direction of rotation. A suitable sensor (notshown) can be employed to determine the height of mast 884 for controlby subcontrol system 118 for packaging device 600.

Suitable mounting structure 916 is provided to mount container graspingdevice 764 to a desired location, such as within cabinet 602. A slot andkey arrangement between shaft 886 and mast 884 permits mast 884 to bevertically translated either up or down while shaft 886 is rotated.

Mounted on the upper end of mast 884 is a suction device 918 whichincludes a suction cup 920, a source of vacuum (not shown) for suctioncup 920 and a release valve (not shown) for releasing the vacuum tosuction cup 920. Vacuum can be supplied from within mast 884 to suctioncup 920 by a suitable connection as is known in the art.

Container bottom urging device 766 consists of a mast 922 that isvertically translatable up and down by suitable apparatus (not shown).Such apparatus can be similar to vertical translation mechanism 790previously described with respect to container retrieving and graspingdevice 762. Preferably, mast 922 has a blunt end 924.

In operation, container retrieving and grasping device 762 selects anappropriately sized container from container storage magazine 638 asdirected by the control system for food packaging device 600. Afterretrieving the container, which in this case is container 611, containerretrieving and grasping device 762 moves container 611 to a position asindicated in FIG. 40 against suction cup 920 so that opposed sidewallsof container 611 are grasped by suction cups 840 and 842 of containergrasping member 778.

Next, as shown in FIG. 41, container grasping member 778 is movedlaterally away from suction cup 920 while maintaining suction on suctioncups 840, 842 and 920. Container 611 is partially erected as shown inFIG. 41 with bottom 611 b depending downwardly slightly. Containerbottom urging device 766 is then activated as illustrated in FIG. 42 tourge bottom 611 b of container 611 upwardly into the fully erectedposition. Container grasping member 778 is released and retracted fromcontainer 611 and returned to a horizontal up position to select anotherunerected container for erection.

Next, mast 884 is rotated approximately 90° by motor 890 to placecontainer 611 in discharge position 710 of food dispensing chutemechanism 608. Food dispensing chute mechanism 608 is then lowered todischarge French fries FF therefrom and into container 611. Any Frenchfries that are not received into container 611 are collected by overflowfood collection member 613 which is then rotated clockwise in thedirection of arrow X as shown in FIG. 41 to recycle such French fries toupper chute 686 for subsequent delivery to another container. After theFrench fries are dispensed from food dispensing chute mechanism 608,cylinder 700 is retracted placing food dispensing chute mechanism 608 inthe upper position as shown in FIG. 44. Mast 884 can then be rotatedback and forth slightly (e.g., such as 2° to 20°, for example) tosimulate shaking to dislodge any loose French fries or dangling Frenchfries in container 611 and any dislodged French fries will then fallinto overflow food collection member 613 for subsequent recycling. Mast884 can also be raised and lowered slightly and relatively quicklyeither before, during or after the angular rotation to further simulateshaking. Thereafter, mast 884 is rotated approximately 180° untilcontainer 611 is directly over container-receiving receptacle 612 asindicated by T in FIG. 44. Mast 884 is then lowered by operation ofcarriage system 898 until the bottom of container 611 rests incontainer-receiving receptacle 612. Then, the vacuum supplied to suctioncup 920 is released and suction cup 920 releases from container 611.Mast 884 can then be rotated 90° so that it is in position to receiveanother container to be erected.

Container-receiving receptacle 612 is then transported via conveyorsystem 614 which will now be described in detail.

Conveyor system 614 and portions or elements thereof are illustrated invarious figures including FIGS. 1, 25-29 and 45-50.

Conveyor 614 includes, in the illustrated embodiment, raceway 620 whichcan be formed along the surface of countertop 636 or on some othersurface as desired. Raceway 620 is preferably in the form of acontinuous loop raceway and is defined by spaced apart guides 620 a and620 b mounted to countertop 636 to guide receptacles 612. Conveyorsystem 614 includes one or more and typically a plurality ofcontainer-receiving receptacles 612 which are illustrated in detail inFIGS. 46-50. Conveyor system 614 includes a first gate 926 and secondgate 928. First gate 926 is movable and typically second gate 928 can bestationary as hereinafter described.

Conveyor system 614 also includes structure for causing movement ofcontainer-receiving receptacle 612. In the illustrated embodiment,container-receiving receptacles 612 are moved via an endless loop 930that can be located beneath countertop 636. Endless loop 930 carries aplurality of magnets 932 as illustrated in FIGS. 45 and 49, for example.Magnets 932 are spaced along endless loop 930. Endless loop 930 maycomprise a chain or other suitable structure that can be driven by adrive system that includes sprockets 934, 936, 938 and 940. One ofsprockets 934, 936, 938 and 940 can be a driven sprocket.

Any suitable endless loop 930 can be utilized such as a belt or a chain.Pulleys could be used in place of sprockets 934-940. The route ofendless loop 930 follows the route of raceway 620.

Container-receiving receptacle 612 typically includes a base 942 and acontainer-receiving well 944 located over base 942. Base 942 includes anenclosed compartment 946 which can be conveniently accessed by a baseplate 948 located along the bottom of base 942 that is fastened to base942 by suitable fasteners 950. Contained within enclosed compartment 946is a magnet 952.

Container-receiving receptacle 612 follows the movement of magnet 932due to magnetic attraction between magnets 932 and 952 thereby causingmovement of container-receiving receptacle 612 along raceway 620.

Enclosed compartment 946 is dimensioned to permit magnet 952 to be freeto rotate therein allowing container-receiving receptacle 612 to bereadily guided by rails 954 and 956 that are raised above countertop636.

Movable gate 926 prevents movement of container-receiving receptacle 612located thereat as illustrated in FIG. 45. This ensures thatcontainer-receiving receptacle 612 is in position to receive a loadedcontainer of French fries, such as container 611 from container graspingdevice 764. After a filled container is placed on container-receivingreceptacle 612 adjacent movable gate 926, gate 926 is automaticallyremoved by a suitable mechanism (not shown) to permitcontainer-receiving receptacle 612 thereat to be moved by conveyorsystem 614 until French fry container 611 contained therein contactsgate 928 or receptacle 612 contacts another receptacle that is locatedat pick up area 622 as shown in FIG. 45. Once container 611 is movedfrom receptacle 612 b, receptacle 612 b is then free to move alongraceway 620 and passes underneath second gate 928, which can be astationary gate. Alternatively, second gate 928 could be a movable gateand could be located at a level that directly prevents movement ofreceptacle 612 b. After receptacle 612 b passes underneath second gate928, receptacle 612 a is moved into the position formerly occupied byreceptacle 612 b provided that receptacle 612 a has a French frycontainer thereon which would then cause receptacle 612 a to be stoppedat gate 928. Similarly, when that container is removed from receptacle612 a, receptacle 612 a would then be free to pass underneath gate 928and around that portion of raceway 620 until encountering gate 926 oranother receptacle that is stopped by gate 926.

Referring to FIGS. 51-60, there are illustrated various views of Frenchfry cartons that are useful in accordance with the present invention.The French fry cartons depicted in FIGS. 51-60 are particularly suitablefor use in conjunction with the present invention since the cartonsreadily stand upright without assistance and can be erected by automatedcontainer handling system 610, previously described.

FIG. 51 illustrates a front elevation view of a carton 1012 that isparticularly suitable for containing French fries, for example. Carton1012 is illustrated in FIG. 51 in an erected or opened position andincludes a pair of opposed curved sidewalls 1014 and 1016 and a bottompanel 1018.

Carton 1012 can be stacked in a collapsed configuration and stored in asuitable magazine, such as container storage magazine 638 as previouslydescribed. When in a collapsed position, carton 1012 is particularlysuited to being opened or erected by pulling sidewalls 1014 and 1016apart and urging bottom panel 1018 upwardly, as described with respectto the erection or opening of container 611 by automated containerhandling system 610. Container or carton 611 is of a design that issimilar to carton 1012.

Carton 1012 also includes two supporting legs 1020, 1022 that extenddownwardly from the lower portions of the overlapping edge portions ofsidewall 1014 indicated by reference numerals 1014 a and 1014 b in FIG.59 and FIG. 53.

Carton 1012 is capable of standing on its own because of legs 1020 and1022 that extend below bottom panel 1018 when carton 1012 is open orerected.

Carton 1012 can be constructed from a single blank of paperboard whichis illustrated in FIG. 59. When constructed, sidewall edge portions 1014a and 1014 b form flaps that are glued to the edges of sidewall 1016 asindicated in FIG. 54, for example.

Bottom panel 1018 is specially configured to facilitate opening orerection of carton 1012 by an automated carton handling device such asautomated container handling system 610, previously described in detail.Bottom panel 1018 includes intersecting lines 1024 and 1026.Intersecting lines 1024 and 1026 intersect at a generally centrallocation of bottom panel 1018, which panel is generally oval even thoughit may incorporate straight edges 1028 and 1030, for example.Intersecting lines 1024 and 1026 may be fold lines, lines of weakening,score lines or even perforations. All such structures are referred toherein with respect to intersecting lines 1024 and 1026 of bottom panel1018 only as “fold lines.” Typically, the intersection of fold lines1024 and 1026 form an angle in the range of from about 60° to about120°. In one embodiment, the intersecting bottom panel fold lines areoriented such that one of said lines (fold line 1024 in FIG. 59) isnormal or at least generally normal to curved sidewalls 1014 and 1016.In such embodiment, the other of the intersecting fold lines (in thiscase fold line 1026) is at least generally parallel to curved sidewalls1014 and 1016.

Preferably, fold line 1024 extends from sidewall 1014 to sidewall 1016.

As previously mentioned, carton 1012 is foldable to a collapsed positionwith sidewalls 1014 and 1016 being planar and in contacting overlyingrelation to each other with bottom panel 1018 being divided into twooverlying panels 1018 a and 1018 b by intersecting fold line 1026.

Preferably, bottom panel 1018 includes two additional fold lines 1032and 1034 on either side of fold line 1024 that extend from one cartonsidewall to the other, in this case from sidewall 1014 to sidewall 1016.Secondary fold lines 1032 and 1034 further facilitate the opening orerection of container 1012 with an automated device such as automatedcontainer handling system 610.

FIG. 58 illustrates a carton 1036 that is similar in construction tocarton 1012 previously described except that carton 1036 is of adifferent size.

Preferably, carton 1012 is configured such that the width of the base isrelatively narrow and the sidewalls 1014 and 1016 flare outwardly sothat container 1012 is substantially wider at the top (from about 1.6 to2 or more times the base width). This allows relatively large and tallcontainers to be placed in an automobile cup holder CH as depicted inFIG. 56.

Referring to FIG. 2, there is illustrated an alternate embodiment of anautomated food processing system 101 in accordance with the invention.Automated food processing system 101 includes a food dispensing device201 which is similar to food dispensing system 200, previously brieflydescribed, where like reference numerals represent like elements. Fooddispensing device 201 includes fewer uncooked bulk food dispensingcontainers 204 and additional magazine food dispensers that are similarto magazine food dispenser 206, previously referred to. Otherwise,dispensing device 201 is similar to dispensing device 200 previouslydescribed.

Automated food processing system 101 also includes fry device 400 whichhas been described.

One primary distinction between automated food processing system 100 andautomated food processing system 101 is that automated food processingsystem 101 does not include an automated packaging device such asautomated packaging device 600. In place of food packaging device 600, afood storage device 635 is provided. Food storage device 635 allows foodcooked by food frying device 400 to be stored in a heated environmentfor subsequent manual processing. As configured in FIG. 2, food storagedevice 635 includes separate product receiving receptacles 637, 639, 641and 643. Each receptacle 637, 639, 641 and 643 is dedicated to receivingfood from a respective one of fry wheels 410, 412, 414 and 404,respectively. In addition, each receptacle 637-643 can have placedtherein a suitable container to receive food, such as handled trays 645,647, 649 and 651.

As illustrated in FIG. 2, a food item F is being discharged from frywheel 414 down a chute 653 and into handled tray 649 contained withinheated receptacle 641. Food item F can be stored therein for a period oftime until it is ready for subsequent processing.

Referring to FIGS. 62 and 63, there is illustrated heated receptacle 643in a cross-sectional view and FIG. 63 is a cross-sectional view takenalong line 63-63 of FIG. 62 showing the entire width of receptacle 643.

As illustrated in FIGS. 62 and 63, heated receptacle 643 is a heatedwell having a heating element that heats sidewalls 962, 964, 966 and 968as well as bottom 970 of heated receptacle 643. Heating element 960 isin close proximity to walls 962, 964, 966 and 968 as well as bottom 970.Heating element 960 may be composed of a single heating element ormultiple heating elements as desired. Suitable controls may be providedto adjust the temperature of walls 962-968 as well as bottom 970 ofheated receptacle 643. In addition, suitable insulation 972 can becontained within the cavity that is defined by cabinet 974 of foodstorage device 635, which is partially shown in FIGS. 62 and 63.

Preferably, handled trays 645-651, such as handled tray 651 depicted inFIGS. 62 and 63 are dimensioned such that they are in close proximity towalls 962-968 and bottom 970 when placed in heated receptacle 643.

Tray 651 may be constructed of any suitable material. In addition, awire basket which can include a handle may be used as an insert for tray651, in which case food CN is contained in the wire basket and tray 651functions to collect excess oil from food CN, in which case tray 651desirably would not include a handle.

Food packaging device 600 may optionally include food seasoning device616, which is illustrated in detail in FIGS. 65-68. Food seasoningdevice 616 includes a hopper 972, a metering wheel 974, a wheel drivesystem 976, a dispensing tube 978 and a dispensing head 618.

Hopper 972 is configured to hold a desired bulk quantity of a seasoningmaterial, such as salt S. Bulk hopper 972 includes a lid 982 that can beremoved to replenish the supply of salt S contained therein. Hopper 972can have a bottom with inwardly extending sidewalls 984 to facilitatethe dispensing of material from bottom 986 of hopper 972 which mayinclude a dispensing tube 988.

Metering wheel 974 is located beneath bottom 986 and dispensing tube 988to receive a charge of salt or other seasoning therefrom. Metering wheel974 includes a cavity 990 for receiving a charge of salt from dispensingtube 988. Metering wheel 974 is rotatably mounted in a housing 992 andcan be rotated about the longitudinal axis of metering wheel 974 tocause cavity 990 to be directed downwardly which thereby causes theseasoning or salt contained in cavity 990 to fall by gravity therefrom.

Metering wheel 974 is suitably rotated by wheel drive system 976. Wheeldrive system 976 can be controlled by a suitable electronic controlsystem that can form part of the food packaging device 600. Typically,in operation, when French fries FF are dispensed from one or more of frywheels 404, 410, 412 and 414 onto chute 604, a suitable sensing device(not shown) senses the presence of French fries and activates wheeldrive system 976 of automated food seasoning device 616 to discharge apredetermined quantity of seasoning, such as salt, onto the French friesthat traverse chute 604.

Dispensing head 618 can be located in a desired position to applyseasoning to the food traversing chute 604. As illustrated in FIG. 3,for example, dispensing head 618 can be located towards a bottom portionof inlet chute 604 and may extend over a portion of rotatable fooddispensing member 606.

Wheel drive system 976 as illustrated in FIGS. 65-68 includes a solenoidplunger 994 for driving a linkage 996 that is connected to meteringwheel 974 to impart rotation to metering wheel 974. Linkage 996 includesa crank arm 998, one end of which is connected to a central portion ofmetering wheel 974 and the other end is connected to a lever arm 1000which, in turn, is connected to solenoid plunger 994. Lever arm 1000 canbe driven by solenoid plunger 994 which, in turn, causes crank arm 998to be driven, thereby rotating metering wheel 974 sufficiently to causecavity 990 to be directed downwardly, thereby permitting any seasoningor salt contained therein to be dispensed therefrom.

A collection funnel 1002 is disposed at the discharge end of housing 992and connects to dispensing tube 978. Dispensing tube 978 is, in turn,connected to dispensing head 618.

Dispensing head 618 can include a plurality of vanes 1004 forfacilitating dispersion of seasoning dispensed therefrom. Asillustrated, there are four vanes 1004 spaced 90° from each other.

Dispensing tube 978 has a lower end portion 1006 that terminates somedistance above dispensing cone 1008 of dispensing head 618. In oneembodiment, lower end portion 1006 of dispensing tube 978 may terminateapproximately 0.25 inches from the tip of dispensing cone 1008.

Dispensing cone 1008 includes a plurality of holes 1010 that are arrayedthrough dispensing cone 1008 to facilitate the distribution of seasoningor salt. In operation, as salt or seasoning is dispensed through lowerend portion 1006 of dispensing tube 978, the seasoning strikes the topportion of dispensing cone 1008 and is directed into four quadrants viavanes 1004. As the seasoning traverses the surface of dispensing cone1008, some of the seasoning falls through holes 1010 in dispensing cone1008. Note that not all of holes 1010 are labeled, for purposes ofclarity in the Figures. Other salt or seasoning particles do not fallthrough holes 1010 but fall off the lower end of dispensing cone 1008.Still other seasoning particles bounce or are otherwise deflected offthe top surface of dispensing cone 1008 and fall a lateral distanceremoved from dispensing cone 1008. In this manner, a good distributionof seasoning is achieved over a relatively large area.

In one embodiment, food packaging device 1600 is illustrated orpartially illustrated and elements useful in connection with foodpackaging device 1600 are illustrated in FIGS. 74, 76 and 86-91. Foodpackaging device 1600 includes a cabinet 1602, inlet chute 1604, saltingdevice 1606, holding bin 1612, container filling device 1614, containerhandling system 1622 and elevator 1628. Food packaging device 1600 canbe French fry containers or cartons or other containers as desired.

Referring to FIGS. 86-89B, there is illustrated container storagemagazine 1630, which can form part of food packaging device 1600.Container storage magazine 1630 is configured to store a plurality ofdifferent sized food containers, in this case French fry cartons in anunerected form. Typically, container storage magazine 1630 will beconfigured to hold a variety of different sized containers. In theillustrated embodiment, the containers are individual portion-sized andare of a type having opposed sidewalls connected by a collapsiblecontainer bottom. Typically, the rear sidewall extends higher than thefront sidewall. Such containers are well known in the art and variousnon-limiting examples are illustrated at FIGS. 51-60. In the illustratedembodiment, container storage magazine 1630 can contain four differentsizes of containers.

Container storage magazine 1630 of container handling system 1622includes a base 1632 that is suitably mounted to cabinet 1602.Preferably, container storage magazine 1630 is mounted to be readilyremoved to permit replacement and/or repair and to otherwise permitaccess to other portions of packaging device 1600.

As illustrated, magazine 1630 is composed of four individual magazines1630 a-d, although any desired number can be used. Each magazine 1630a-d includes a face plate 1636 a-d defining apertures 1638 a-d,respectively, each of said apertures corresponding to the profile of adifferent size collapsed carton. Apertures 1638 a-d are dimensioned tobe able to retain a horizontal stack of cartons in a collapsed orunerected condition as illustrated in FIGS. 86-88 in which a pluralityof unerected cartons C-C′″ are stacked therein.

Each face plate 1636 a-d and each aperture 1638 a-d has associatedtherewith a plurality of generally horizontally extending guide members1640 a-d shown with respect to face plate 1636 d consisting of fourmembers each, for maintaining uniform stacks of unerected cartons. Inthe illustrated embodiment, guides 1640 a-d are in the form of L-shapedelongated members. Each set of four guide members is associated with aspecific one of apertures 1638 a-d to define and permit horizontalstacking of a plurality of unerected French fry cartons or containersthat generally are slightly larger in size than the size of apertures1638 a-d, respectively. It is to be understood that other arrangementsto define a container stack can be utilized in accordance with theinvention. For example, in place of guides 1640 a-d other structurecould be utilized, such as upstanding walls or partial walls or othertypes of guides.

Container storage magazine 1630 typically will also include a suitableurging device for each magazine 1630 a-d to urge the stack of containerscontained therein against respective face plates 1636 a-d in directionZZ of FIGS. 89A and 89B, which may be a spring loaded urging device.Each magazine 1630 a-d includes a restraining member 1642 a-d,respectively, for restraining the rear sidewall from relative movementwith respect to the front sidewall. As illustrated, restraining members1642 a-d are in the form of an arcuate spring clip. In addition, a pairof horizontally extending guides 1644 a-d are provided adjacentapertures 1638 a-d to guide cartons as they are removed from magazine1630 and erected.

Container storage magazine 1630 is preferably positioned to permit readyaccess to the front of each container stack through each of apertures1638 a-d by container handling system 1622, which is hereinafterdescribed in detail.

Food packaging device 1600 includes container handling system 1622.Container handling system 1622 is capable of retrieving an unerectedcontainer through any of apertures 1638 a-d of container storagemagazine 1630, erecting the unerected carton and placing the erectedcarton in position on elevator 1628 for delivery to container fillingdevice 1614.

Referring to FIGS. 74, 86, 88-89, there is illustrated containerhandling system 1622 and elements and features thereof. Containerhandling system 1622 includes a container retrieving and grasping device1646 that includes a container grasping device 1648, X-carriage system1650, Y-carriage 1652 and container bottom urging devices 1653 a-d,which are in the form of inclined ramps located adjacent apertures 1638a-d. Any suitable container handling device that performs the functionsof system 1622 can be used, in whole or in part as desired.

Container handling system 1622 is controlled by a suitable controlsystem for food packaging device 1600, similar to the control system forpackaging device 600 as hereafter described.

Container retrieving and grasping device 1646 and portions thereof arebest illustrated in FIGS. 86-89C. Container grasping device 1648includes a carriage follower body 1654, which is mounted to X-carriagesystem 1650, Y-carriage 1652, a Y-carriage follower 1666 and a containergrasping member 1648.

Body 1654 is carried by X-carriage system 1650 that includes and isdriven in a suitable manner such as a toothed belt 1660′ and drive anddriven pulley arrangement 1660 a and 1660 b, which allows for lateraltranslation of body 1654 and the components associated therewith,including Y-carriage 1652 and movable rack member 1656, containergrasping member 1648. Carriage system 1650 includes guide members 1650a,b, a drive mechanism 1660 that includes and is driven in a suitablemanner such as a toothed belt 1660′ and drive and driven pulleyarrangement 1660 a and 1660 b and carriage follower 1654. Carriagefollower 1654 supports Y-carriage 1652, which allows for movement normalto the longitudinal axis of X-carriage 1650 of container grasping device1648.

Guide members 1650 a,b are each an elongated guide that defines thelateral translation movement direction of carriage follower 1654 and issecured within cabinet 1602. A suitable drive motor (not shown) is usedto rotate drive pulley 1660 a. The drive motor can be an AC or DC motoror a stepper or servo motor as desired. Suitable sensors can be employed(not shown) to determine the position of carriage follower 1654 whichdetermines the lateral position of container grasping member 1648.

Carriage follower 1654 is composed of a frame 1662 having guideapertures 1664 a,b in which carriage guides 1650 a,b are disposed. Thus,X-carriage system 1650 provides lateral movement in the direction ofarrows AA as shown in FIG. 88. In this manner, carriage follower 1654and thus container grasping device 1648 and Y-carriage 1652 can belaterally translated as desired.

Container grasping device 1648 can be horizontally moved towards andaway from X-carriage 1650 in the directions indicated by arrow BB inFIG. 88 by operation of a carriage follower mechanism 1666 that formspart of container grasping device 1648 and is guided by Y-carriageguides 1652 a,b. Y-carriage follower mechanism 1666 can be ahorizontally extending carriage system similar to that described withrespect to X-carriage system 1650 and can be controlled in a similarmanner. Alternatively, Y-carriage movement can be accomplished by anactuator, which could be an air cylinder, for example, not shown. Tograsp a container, suction cups are pressed against a surface of thecontainer and the vacuum is activated.

When container grasping device 1648 is in position adjacent containermagazine 1630 as shown in FIG. 89A, it is utilized to grasp and retrievea desired size of container from one of the apertures 1638 a-d fromcontainer storage magazine 1630. For this purpose, container graspingdevice 1648 includes a suction cup device 1668 which includes at leastone suction cup 1670 and in the illustrated embodiment two suction cups1670 and 1672 typically arrayed to conform to the erected carton frontwall and thus typically will be in substantially the same plane forgrasping a container having a surface to be grasped by both suction cups1670 and 1672 in generally the same plane. Suction cup device 1668 alsoincludes a vacuum source, a release valve and a suitable vacuum line(not shown) which connects suction cups 1670 and 1672 to the vacuumsource, which can be similar to that arrangement as illustrated in FIG.30, for example. In operation, when suction cups 1670 and/or 1672 engagea container or other member to be grasped, the vacuum source isactivated to supply vacuum to suction cups 1670 and 1672, such as tograsp and retain a container from one of apertures 1638 a-d of containerstorage magazine 1630.

In a typical operation, container retrieving and grasping device 1648will be operated to position suction cups 1670 and 1672 adjacent and inoperative contact with a container to be selected from container storagemagazine 1630 as shown in FIG. 89A. Suction cups 1670 and 1672 are at adesired height so that they engage a container contained at the front ofcontainer storage magazine 1630. The vacuum source is activated andcontainer grasping device 1648 is moved away from magazine 1630 toremove a container from a desired one of apertures 1638 a-d of containerstorage magazine 1630 as shown in FIGS. 89A and 89B. Carriage system1652 can be activated to move container retrieving and grasping device1648 laterally away from magazine 1630, which causes the selectedcontainer to be pulled from the selected magazine, which in this case ismagazine 1630 a. Guides 1644 a maintain container C in proper lateralposition as container C is pulled through aperture 1638 a in thedirection of arrow EE. Restraining member 1642 a restrains the rear wallof container C as it is pulled through aperture 1638 a and a jet ofcompressed air from air nozzle 1674 facilitates the separation of thefront and rear sidewalls of container C while at the same time thebottom of container C is urged up as it traverses inclined ramp 1653 ato cause container C to be erected. Such lateral movement can becontrolled by properly positioned sensors as known in the art. Forexample, one sensor each can define the position to retrieve a containerfrom apertures 1638 a-d, respectively. Another sensor can be positionedto define the home or fully retracted location of container graspingdevice 1648 after erection of the container that has been retrieved fromone of apertures 1638 a-d of container storage magazine 1630. Aftererecting the container, X-carriage 1650 moves the erected container C inthe direction of arrow FF to elevator 1628 and releases the erectedcontainer C by releasing the vacuum to suction cups 1670 and 1672,depositing it in receptacle 1628′ of elevator 1628 as shown in FIG. 89C,where container C is then lowered in the direction of arrow GG byelevator 1628 to a suitable position for container filling device 1614.The vacuum applied to suction cups 1670 and 1672 can be released byoperation of a release valve (not shown) or other device which permitssuction cups 1670 and 1672 to disengage and release the container thathad been grasped.

For example, a container bottom urging device similar to containerbottom urging device 766 could be used in place of inclined ramps 1653a-d. In addition, the opposed sidewalls of the French fry containercould be separated by a device such as container handling system 610,which includes suction devices that attach to each side of an unerectedcontainer after the container is removed from a container magazine. Forexample, see FIGS. 40-42, for example. As a non-limiting example, such adevice could be located in front of a portion of container magazine1630, for example, using container grasping device on one side of thecontainer and a device such as container grasping device 764 (shown inFIGS. 38 and 40, for example) on the other side of the container to beerected.

Elevator 1628 may be constructed in any suitable manner. In theillustrated embodiment, elevator 1628 is a rodless cylinder that carriesa receptacle 1628′ which is well-shaped and suitable to contain anerected French fry container. Receptacle 1628′ is movable by elevator1628 from a first or raised position as illustrated in FIG. 89C adjacentor otherwise in a suitable position for container handling system 1622to a second or lowered position suitable to be handled by containerfilling device 1614 as partially shown in FIG. 89D.

As shown in FIG. 89D, scoop or funnel 1710 of container filling device1614 is inserted into container C, in the direction of arrow HH andgrasps container C from receptacle 1628′ when receptacle 1628′ is in thesecond or lowered position. Container filling device 1614 operates tofill erected French fry containers that typically will be individualportion-sized French fry containers. Container filling device 1614 iscomposed of a multi-link mechanical arm 1616 that includes an end-of-armtool 1626, that includes scoop or funnel 1710, is capable of grasping aFrench fry container, moving to an appropriate position via carriage1618 and mechanical arm 1616 for scooping it into French fries FFcontained in holding bin 1612 in the direction of arrow NN (see FIG.89E) to fill French fry container C with French fries, relatively gentlyshaking the filled French fry container to seat the French fries in thecontainer and to dislodge any loosely contained French fries whilecontainer C is slightly inclined, thereafter moving container C to anupright position as indicated by arrows II and JJ (see FIG. 89F) bymoving second link 1692 and third link 1694 in the direction of arrowsKK and LL, respectively, as shown in FIG. 89H. Thereafter, arm 1616deposits and releases the filled French fry container at drop-offlocation 1620 as shown in FIG. 89I by moving container C in a generallydownward direction indicated by arrow PP, which location typically willinclude a holding structure configured to receive and contain the filledFrench fry containers from where they can be picked up by a humanoperator, for example.

Mechanical arm 1616 can be configured and operated to generally mimicthe arm, wrist and hand action of a human operator in scooping Frenchfries into a French fry container and to shake the filled French frycontainer to remove loosely contained French fries and to more firmlyseat French fries contained in the container.

In the illustrated embodiment, which is best shown in FIGS. 74, 76,89G-H and 90A-F, multi-link mechanical arm 1616 includes first, secondand third links 1690, 1692 and 1694, respectively, and an end-of-armtool 1626 that is carried by third link 1694.

First link 1690 is pivotally connected to a mast 1696 via a pivotconnection 1698. Mast 1696 is secured to a carriage follower 1712 andcan be horizontally translated via carriage 1618. First link 1690 isconnected to second link 1692 at adjacent ends thereof via pivotconnection 1700 allowing second link 1692 to pivot relative to firstlink 1690. Adjacent an opposite end of second link 1692 to pivotconnection 1700 is connected third link 1694 to second link 1692 via athird pivot connection 1702.

End-of-arm tool 1626 is rigidly connected to third link 1694 by asuitable structure, such as welding or use of a threaded fastener, forexample. End-of-arm tool 1626 is configured as a French fry scoop orfunnel and is configured to facilitate the filling of French frycontainers which are held by end-of-arm tool 1626. End-of-arm tool 1626includes a French fry container grasping mechanism 1704. French frycontainer grasping mechanism 1704 is composed of a movable finger 1706and an actuator 1708 for movable finger 1706. Thus, when French fryscoop or funnel 1710 of end-of-arm tool 1626 is inserted into an erectedFrench fry container C as illustrated in FIG. 90D, actuator 1708operates to move movable finger 1706 to a closed position in whichmovable finger 1706 moves in the direction of arrow MM and clamps therear sidewall C′ of container C against French fry scoop 1710 therebysecuring container C in a fixed position at the outlet end of French fryscoop or funnel 1710. In this manner, mechanical arm 1616 can grasp acontainer C that has been placed in receptacle 1628′ of elevator 1628when in the second or lowered position, as illustrated in FIGS. 89D and90B.

Carriage 1618 for mechanical arm 1616 allows mechanical arm 1616 to belaterally moved in the direction of arrow AA to desired locationsdepending on the task that is to be performed by mechanical arm 1616 asindicated in FIG. 90A, for example. Thus, carriage 1618 allowsend-of-arm tool 1626 to be laterally moved from an erected carton pickuplocation as illustrated in FIG. 90B to a French fry container fillinglocation where end-of-arm tool 1626 can be scooped through a quantity ofFrench fries contained in holding bin 1612 to thereby cause the erectedFrench fry container to be filled with French fries and to transfer thefilled French fry container to drop-off location and holding structure1620, where mechanical arm 1616 releases the filled French fry containerfor subsequent pickup by a human operator, for example.

Carriage 1618 includes a carriage guide 1618′ and a carriage follower1712 that traverses carriage 1618 and to which is mounted mast 1696.Lateral translation along carriage 1618 of carriage follower 1712 isaccomplished by any suitable structure and may be by means of a rodlessair cylinder. Carriages 1650, 1652 and 1608′ can also be driven by arodless cylinder or any other suitable device.

Mechanical arm 1616 is composed of three links that are pivotallyinterconnected permitting movement so that each of the links arepivotable in parallel planes which in the illustrated embodiment areeach in a vertical direction. Pivotable movement of each link isaccomplished by a suitable actuator 1714, 1716 and 1718, one for each ofpivot connections 1698, 1700 and 1702, respectively. Actuators 1714,1716 and 1718 can be any suitable type of actuator to provide thedesired rotational movement including, such as, an electric motor, anair driven motor and a stepper motor, for example. Actuator 1714 causesrotation of first link 1690 relative to mast 1696 about pivot connection1698. Actuator 1716 causes rotation of second link 1692 in a verticalplane about pivot connection 1700 and actuator 1718 causes rotation ofthird link 1694 in a vertical plane about pivot connection 1702. Variousmovements of mechanical arm 1616 of first, second and third links1690-1694, respectively, are illustrated in FIGS. 76, 89E-H and 90A-F,for example.

In one illustrated embodiment, filled French fry collection drop-offlocation and holding structure 1620 is configured as an inclined holdingrack 1730 as illustrated in FIG. 89I, for example. Inclined holding rack1730 includes a plurality of separate lanes, namely, first lane 1732,second lane 1734 and third lane 1736, for receiving small, medium andlarge size filled containers of French fries, as illustrated in FIG.89I.

Alternatively, a carousel-type structure may be provided, namely,holding carousel 1738, as illustrated in FIG. 91. Holding carousel 1738is composed of a plurality of radially extending individual compartments1740 a-c, the number of compartments being limited by the size ofholding carousel 1738 and the desired size for each compartment. Asuitable drive mechanism 1742, which may be an electric motor isprovided for causing rotation of holding carousel 1738.

The Control System and Method

In one embodiment, the System Master Controller comprises a Server (PC),a router/hub, and a touch-screen monitor (user interface). The Mastercan utilize existing technology to integrate, to manage, to control, andto coordinate information flow of and through the various subsystems foroverall system operation. The network technology is fully compliant withthe latest version of the industry's NAFEM Protocol.

Control System Features

Referring to FIGS. 69-73, the primary functions of the Control Systemare to receive order information from the POS and to connect andcoordinate all operating subsystem controllers with the MasterController so that operational commands and functional information canbe communicated and displayed. The result is that all the dispensing,fry and packaging modules function as one integrated fried foodsproduction system.

In one embodiment, the Control System is event and demand driven. Thatis, nothing happens unless a functional component or subsystem receivesa command signal to initiate the action. In a normal operation mode, thePOS will provide virtually all of the system order demands. These cantake the form of a string of two-bit Order Events. Typically this willbe a quantity and an item (for example, 2 each regular size fries). Theproduct description can consist of both the food item and its portionsize, treated as one bit of information.

The Control System information can be categorized into Order Events,Inbound Events, and Outbound Events. The Order Events come fromprimarily the POS system, the historical kitchen management system (KMS)data, or the touch-screen Monitor if a manager wants to override theautomatic ordering. KMS is a database of information of, for example,the sales rate of various products versus day and time. The Order Eventsdictate and demand the operation and performance of the automationcontrol system for production. The Inbound Events information includesmessages generated by subsystem controllers other than the POS or KMS.The Outbound Events include typical command messages issued by theMaster Controller specifying functions to be performed by individualsubsystem controllers.

In one embodiment, the Master Controller is configured to monitorperiodically or continuously the network for events to occur. Once anevent takes place and a signal is sent on the network, the MasterController identifies the source of the signal, then compares it to theprogrammed schedule of events within its memory, and reactsappropriately, either sending out a new command, showing a display,storing information in memory, or all of the above.

An important source of data for the Control System can be the KitchenManagement System (KMS). The KMS is a historical database of operationalinformation. This information can be used to set the workstationconfiguration, process settings, inventory levels, and set a level ofproduction in advance of actual customer demand orders. This interfacecan be a two-way connection, so that all operational data from the FriedFoods Workstation can be received and stored in the KMS and/or theControl System, or evaluated, adjusted, and re-entered to “fine-tune”the process on a continuing basis.

Generally, the Control System can comprise two loops, shown in FIG. 70.The primary loop is the “Order-to-Package” loop, whereby the MasterControl takes an Order Event input from the POS and directs theappropriate Packaging Module subsystem to package and deliver anappropriate portion of product. A secondary loop is the “BufferReplacement” loop, where the Master Controller receives an Inbound Eventsignal from the Packaging Module that its buffer inventory ofready-to-package fried product is low and additional product must bedispensed and fried. As currently specified, all products other thansalted French fries typically can have a default buffer inventory ofzero, meaning that an order for that (other) product will immediatelyinitiate a full dispense-fry-package (if packaged by the System)production routine.

In accordance with one aspect of this embodiment of the Control System,the Fryer Module vat operation is not directly controlled by theproduction demand cycle. Each fry vat of the fry module will operatecontinuously and on a pre-set uniform operating cycle. Frozen product isdropped into the fry module when additional inventory is called for. Theproduct is fried according to the pre-set cooking cycle and then isdumped into the Packaging (or Protein) Module receiving apron. None ofthe cooking cycle is affected by order demands, or inventory conditions.In one embodiment, the Control System can vary the time betweenincremental rotation and speed of rotation of fry wheel 410 toaccommodate for varying conditions, such as the level of cooking oil inthe fry vat. The level of cooking oil can vary as a result of the amountof product that is being fried in a particular fry vat, since productpresent in the fry vat displaces cooking oil, thereby raising the levelof cooking oil in the fry vat particularly since the product is heldbelow the cooking oil surface during a cooking cycle.

Preferably, to ensure the workstation reliability and system uptime,extensive control redundancy can be provided. As a result, the controlsubsystems for each Fryer Module vat and each Dispensing Module chuteare designed and constructed as individual units that operate even ifone or more subsystem fails.

Additionally, the control of the Dispensing Module freezer environmentand operation can be an independent subsystem.

Preferably, the Control System includes the capability to operate allmodules individually. This allows the operator to disconnect and removea module from the network and operate the remaining modules in asemi-automatic method, manually performing some of the operations.Preferably, there are controls on each module that permit an operator tooperate that module's functions locally.

Orders for product are preferably processed sequentially as they arereceived, although the specific products within a customer order may bearranged in a logical manner as desired. The Monitor will display allproducts being processed by the workstation from the time the order isreceived until it is removed from the workstation. The status of eachproduct that is ordered can be tracked in its various stages including,for example, on order, packaged and ready to pick up, ready to manuallypackage, and held too long.

Preferably, products in the process of being fried can also be tracked,and cooking times for each basket in each wheel will count down to whenproduct is ready to package.

Master Controller

In one embodiment, the Master Controller 110 hardware may suitablycomprise, or equivalent:

-   Intel Pentium III (or higher) with 1.0 GHz (or higher) CPU-   Ethernet network interface and hub-   256 MB (or more) system RAM-   20 GB (or more) hard disk drive-   Touch-Screen Monitor Interface-   Plug and Play Touch-Screen Monitor-   SCK Gateway (Ethernet)-   Interconnect cabling (as needed)-   Optional Keyboard and pointing device (mouse) for installation and    maintenance purposes

Typical operating system software requirements are:

-   Windows 2000 professional (or server) SP4 or higher-   A suitable Database Server, such as Fast SCK Version 3.0 (or higher)    from Fast, Inc. of Stratford, Conn.-   Fast SCK Version 3.0 (or higher) Utility Applications (SCK Editor,    SCK Engine, SCK Events, and SCK Site Editor) from Fast, Inc.

The Subsystem Interface Modules provide the functionality to communicatespecific control events (information) conditions, and/or commands to andfrom the Master Controller. These modules typically can be incorporatedinto the circuitry of controller boards. In cases where the networkneeds to interface with a control subsystem (such as PLCs, for example),appropriate imbedded memory interface (input-output) circuit cards knownin the art can be utilized. All of the foregoing hardware and softwareor equivalent is readily available or can be produced by those skilledin the art.

Fryer Controller

The frying of the frozen product is controlled by a combination ofcooking oil temperature and the time the frozen product is immersed inthe cooking oil. Frying is accomplished by moving the frozen productthrough the heated cooking oil by a rotating fry wheel. As previouslydescribed, a programmable stepper or other motor can provide the desiredprecisely controlled movement of the fry wheel.

The following Table I lists typical control parameters and severaloptional parameters that can be used, if desired.

TABLE I Fryer Module Control Signals (One set for each of 4 ProductLanes) Description Input Output Op. Adj. Set Temperature X X ActualTemperature X “Ready” Band Width X Temperature Offset X C or F X X Probe#1 X Heater Relay #1 X Total Cook Time X X Jog Speed X Jiggle Time XCleaner Level X Oil Fill X Cleaner Fill X Probe #2 X Heater Relay #2 XFlex Time X

FIG. 71 depicts a typical motor/fry wheel/basket cycle. Virtually everyparameter can be fixed or adjustable as desired. For example, during onetypical cycle, which may be for a preset period of time that isone-quarter of the cooking time for food contained in a compartment, frywheel 410 is rotated clockwise 45° in the direction of arrow K of FIG.13. After some period of time after the 45° incremental rotation, abasket shaking simulation of back and forth rotation occurs over aperiod of about two seconds. After a 0 to 10-second delay, anotherbasket shaking simulation occurs. Thereafter, a period of time (“BasketLoad Window’) is available for loading another compartment, such ascompartment 436 with a charge of French fries or other food to be fried.Thereafter, a “no load zone” or relatively short period of time towardsthe end of the cycle is set aside just prior to another 45° fry wheel410 rotation in the direction of arrow K, which commences another cycle.During each cycle, three “home routines” can be employed, one after eachrotation of fry wheel 410 to accurately locate fry wheel 410 so that itis properly positioned with the upper end of compartment bottom 432′ ofone of fry wheel 410 compartments adjacent discharge 498 and another ofthe compartments properly aligned to receive a charge of French fries orother food to be fried, such as from food dispensing device 200.

To ensure proper operation of the basket/fry wheel, includingpositioning the unit precisely for smooth loading and completeunloading, the basket/fry wheel position must be constantlysynchronized. To do this, a “homing” sensor circuit can be utilized thatresets the home position after every move of the wheel. This sensorpreferably is electromagnetic and is impervious to dirt and grease buildup and has no moving parts although any suitable sensor can be used.

Dispensing Controller

The Dispensing Module control system 114 separates functions by theproduct delivery lane they support. In one embodiment, where there arefour delivery lanes, there are four control subsystems. Each subsystemcontrols a vibrating product conveyor, a portioning load cell, and adump actuator. Additionally, there are optional module configurationsthat affect the controls design. If lanes 1, 2, and/or 3 are configuredwith bulk food hoppers, a product level sensor can be provided to alertoperators to reload frozen product before the hopper is empty. If eachof lanes 2, 3 and/or 4 is configured with an array of coil magazines forfood items, the controls must sequentially switch power to each of themotors in the lane to maintain a constant flow of frozen product.

Table II lists defined control signal parameters for each of theDispensing Module Lane controllers:

TABLE II Dispensing Control Signals (One set for each of 4 ProductLanes) Description Input Output Load - Small Qty. X Load - Large Qty. XLoad Coil A X Load Coil B X Load Coil C X Load Coil D X Load Coil E XReady to Dump X Vibrator Frequency X Bulk Fill Level X Time Out XOverweight X Clean Out X

Freezer Controller

In addition to properly dispensing products into the Fryer Module,subcontrol system 114 for dispensing device 200 or 1200 must alsomaintain a proper frozen environment for all products. To accomplishthis, another controller subsystem can be provided. Table III lists theapplicable control signal parameters for the freezer subsystem. A safetycircuit interrupts all dispensing activity when the aisle door isopened.

TABLE III Freezer Control Signals Description Input Output Op. Adj. SetTemperature X X Actual Temperature X Aisle Door Open X

The separation of the Dispensing Module controls into these fivesubsystems, when there are five, makes for a convenient mechanicalarrangement in the base of the module, and allows for the requiredflexibility given the configuration options.

In one embodiment, for manual operation, four “dispense” buttons areprovided, one for each lane. One button would cause the release of apre-set portion of the frozen product for that lane. The controlspreferably should be located so the operator could by visual observationdetermine the appropriate fryer basket to make sure the productdispenses into the proper basket.

Packaging Controller

Packaging Controller 118 for the Packaging Module incorporates severalevent signal generators for the control system to sense or read. Themain Packaging Module or device 600 and 1600 elements are depicted inFIGS. 25-29 and FIGS. 86-90, respectively. In one embodiment, thePackaging Module or device control system includes two subsystems withinthe Packaging Module, the packaging subsystem and the heated foodstorage device 635 that can be used in place of packaging device 600 or1600.

The Packaging Subsystem

The packaging control subsystem initially interfaces with the PackagingModule PLC and sends packaging device 600 or 1600 a signal to start thesequential operation of packaging one of an appropriately sized portionof French fries. The actions and reactions of all the electromechanicaldevices (e.g., for device 600: container handling system 610, dispensingmember 606, overflow member 613, load cell 702 and chute mechanism 608and for device 1600: container handling system 1622, elevator 1628,salting device 1606 and carriage 1606′, first and second gates 1608 and1610, and container filling device 1614) can be, if desired, sequencedand controlled by the local on-board controller (i.e., PLC) and notMaster Controller 110.

For device 600, once the container grasping device 764 sets the filledpackage of fries on conveyor 614 and the receptacle load gate 926 opensto allow receptacle 612 to move to the pick up area, a signal will besent back to Master Controller 110 indicating that the particular orderof fries is ready for pick up. Until that receptacle 612 moves to thereturn gate 928 (located at the operator right front of the PackagingModule) and the gate permits receptacle 612 to move therepast afterreceptacle 612 is empty, Master Controller 110 will believe (anddisplay) that the order of fries is waiting to be picked up. Preferably,the crew member will pick up fries from right to left to ensure that theorder sequence is followed and that the oldest fries are served first.

Because the number of receptacles 612 that can fit between gate 926 andreturn gate 928 typically is limited, Master Controller 110 intelligencepreferably keeps track of how many orders of fries are in the pick upcue. This allows audible/visual alerts to be triggered on the Monitor toremind the crew that orders have been waiting. Also, even if orders arepicked out of sequence, the Master Controller will remember what was onan empty receptacle 612 and clear it when it passes return gate 928.

Preferably, the Master Controller is configured to remember the holdtime of each packaged fry order. If the order has not been picked up intime, the Monitor will alert the operator by audible/visual signal to“waste” that order.

For device 1600, once automated mechanical arm 1616 deposits a filledpackage of fries at drop-off location, Master Controller 110 willbelieve and display that the order is ready for pick-up from theparticular lane of rack 1730 or from a particular compartment of holdingcarousel 1738, the rotation of which can be controlled by MasterController 110.

The Secondary Loop

The remainder of control 118 for Packaging Module or device 600 or 1600functions address the secondary loop, “buffer inventory replacement.”Preferably, there are two typical system requirements for the bufferinventory: (1) there must be a minimum amount of fries in member 606 orchute mechanism 608 (for device 1600, in holding bin 1612 and/or onchute 1604) to completely fill the next packaging order (that is, enoughFrench fries to make one portion of a given size given the particularfilling efficiencies of the filling device of packaging module 600 or1600); and (2) the buffer inventory is low and needs to be replenished.

For the first requirement, if there is insufficient buffer inventory tofill the package, chute mechanism 608 or mechanical arm 1614 is disabledor held inactive and an error message alarm is sent. This conditionshould not happen, but the control intelligence prevents packagingdevice 600 or 1600 from under filling an order.

During normal operations, the level of fries in the buffer inventorywill drop to a level where an inventory replenishment order will beinitiated. In that event, Master Controller 110 can signal dispensingdevice 200 or 1200 to start its fill sequence. This process shouldtypically start soon enough that the replacement product can be fried,salted, and added to the dispensing member 606 or to holding bin 1612 oron inlet chute 1604 before the “out-of-product” condition is reached.The KMS data can be integrated into the Master Control intelligence tohelp insure that there is replacement product in process before theactual need arises. This capability minimizes order delivery delayswhile also preventing the dispensing member 606 or in holding bin 1612or inlet chute 1604 inventory growing beyond actual need.

The dispensing member 606 (or holding bin 1612 and/or inlet chute 1604)inventory can be managed in a number of ways, as desired. For example,any of the following can be utilized and implemented by one of ordinaryskill in the art: (a) direct sensors; (b) a load cell that constantlyweighs the buffer inventory; and (c) a dynamic empirical calculation.

The dynamic empirical calculation embodiment may use the MasterController to constantly calculate how much product has been added todispensing member 606 (or holding bin 1612 and/or inlet chute 1604), andsubtract out the portion packaged, any bonus amount, waste, and a safetyfactor. This empirical total will then be compared to pre-set “reload”levels. The formula may also include how much product is in process. Inall cases, the buffer inventory level can be adjusted during the day toreflect actual sales levels.

The controls system design for all other (i.e., non-salted French fries)products is that the same control process would be used, but that the“buffer inventory” for those products may be defaulted to zero. That is,an order for hash browns would immediately signal an “out-of-inventory”condition and launch an “inventory replacement” command to thedispensing device 200 or 1200. Later, if the need arises, controllerintelligence would allow the operator to utilize some buffer inventoryfor these products.

Optionally, a provision can be made for unsalted French fries. UnsaltedFrench fries would be handled like the non-French fries products. Whenan order for unsalted French fries is received, Master Controller 110will signal the Packaging Module to move diverter bar 605. The next loadof French fries coming from the Fryer Module will then be diverted to aportion of chute 604 of packaging device 600 for manual packaging. Theextra unsalted fries can be manually returned to chute 604.

An important feature of the automated system is to maintain productintegrity. One facet of that is to dispose of product that has exceededits authorized holding time. Master Controller 110 will remember wheneach load of French fries came out of fry device 400. The mechanicaldesign of packaging devices 600 and 1600 assures a substantially “firstin—first out” product movement. How long the “oldest” fries have been indispensing member 606 is tracked by Master Controller 110 or packagingdevice controller 118, as desired. Whenever the allowable holding timehas been reached, Master Controller 110 will signal the Packaging Modulesubsystem Controller 118 to start the buffer waste cycle (or thepackaging device Controller 118 can directly control this function). Itis possible that some French fries in the buffer will not have reachedtheir limit, but through control parameter refinement, this can beminimized. Table IV lists the control signals for one embodiment of thepackaging control subsystem:

TABLE IV Packaging Control Signals Description Input Output Op. Adj.Package #1 X Package #2 X Package #3 X Package #4 X Divert Fries XProduce #5 X Produce #6 X Produce #7 X Produce #8 X Produce #9 X DumpBuffer X Buffer Low X Buffer Full X Receptacle Loaded X Receptacle EmptyX Time out - System 610 X Product #5-9 Picked X

Holding Controller

The other control subsystem is that dedicated to holding product atproper temperatures. Generally, a standard temperature controller withtimer channels to manage all holding functions can be utilized, as isknown in the art.

Table V lists the various control parameters for the holding controlsubsystem for food holding device 635:

TABLE V Holding Control Signals Description Input Output Op. Adj. BufferTemp Set X X Buffer Temp Act X Pick Up Temp Set X X Pick Up Temp Act XApron Temp Set X X Apron Temp Act X Holding Temp Set X X Holding TempAct X Holding Time #1 Start X Holding Time #1 End X Holding Time #2Start X Holding Time #1 End X

Touch-Screen Monitor

The Touch-Screen Monitor is the primary system user interface and can beconsidered part of the Master Controller configuration. The Monitor hasfour main functions: (1) display the status of fried foods orders; (2)allow the operator to manually control the system; (3) alert theoperator to any needed manual intervention; and (4) allow the operatorto reconfigure the workstation and/or change the individual operatingparameters.

The Monitor display can be configured as desired. Preferably, the maindisplay menu is simple, uncluttered and only presents the basicinformation needed to track ongoing order status. A sample Monitordisplay layout is shown in FIG. 72.

In the illustrated embodiment, products on order would appear ashorizontal rows of the appropriate product (type and portion size) icon,reading from the left edge of the screen. All products from a single POScustomer order would appear on a single line. As additional POS ordersare entered, the screen would refresh, moving the older orders down aline. Products on order, and not yet ready for pick up would appear asgold icons.

Across the bottom of the screen would appear the same number oflocations as there are packaging device 600 receptacles 612 in the pickup zone. As packages of fries are placed on receptacles 612 and thereceptacles 612 travel within the pick up zone, the appropriate iconwill disappear from the “on order” line and reappear as a green icon inthe spot where its receptacle is. When a package is removed from areceptacle and that receptacle passes return gate 928, the display iconwill disappear from the screen.

In one embodiment, should the “hold timer” for a packaged product expirebefore it is picked up, its green icon will change color (i.e., to red)and/or flash. In another embodiment, an audible alarm can be provided aswell, indicating clearly that this product should be wasted.

Across the top of the screen is a line of control “buttons.” There canbe one for each product (again, type and portion size). The system isprogrammed so that touching the button on the screen will enter an orderfor one each of that product. There is also a screen button at the upperright corner of the screen that enables the operator to change thescreen display to the “Settings” screen.

The “Settings” screen layout is depicted in FIG. 73. From this screen,the operator may now configure all the operating settings for theproduct to be run in each product lane. The individual settings mayinclude dispensing load size(s), fry vat temperature, cooking cycletime, buffer inventory level, packaging device Module heater setting,and other settings as desired. In this embodiment, all settings for aparticular product are linked to that product. The operator can merelyscroll in each product lane and signify the product that will be run init. Master Controller 110 will then set all operating parameters forthat product. If it is necessary to check or adjust an individualcontrol setting (such as cook time), the operator can scroll through theitems in the “settings” box for that lane and product. Then, using the“up” and “down” keys, the operator can readjust the setting and pressthe “enter” key to reset.

If required, a secure “manager only screen” can be configured to allowsomeone to adjust and/or reset selected operating parameters. Access tothis screen and these settings would require some type of password toprevent any non-authorized store employee from changing basic systemparameters.

Operator alert messages or alarms (e.g., bulk product low—refill now:“bridging/time out”—clear lane 2; etc.) will appear as an “error messagebox” in the center of the screen, along with some type of audible alarm.

While the invention has been described with respect to certain preferredembodiments, as will be appreciated by those skilled in the art, it isto be understood that the invention is capable of numerous changes,modifications and rearrangements and such changes, modifications andrearrangements are intended to be covered by the following claims.

1. A tray for vibratory conveying food articles from a hoppercomprising: a tray body, a food inlet portion and a food outlet portion,the food inlet including an upwardly extending dividing member fordividing the tray into at least two food inlet conveyor passageways, theinlet conveyor passageways merging into a single food passageway thatextends to the food outlet portion.
 2. The tray of claim 1 wherein saidsingle food passageway is non-linear.
 3. The tray of claim 2 wherein thesingle food passageway has a zigzag configuration.
 4. The tray of claim2 wherein the single food passageway has a serpentine configuration. 5.The tray of claim 1 wherein the dividing member is saddle-shaped.
 6. Thetray of claim 1 wherein the single food passageway causes food the sizeof chicken nuggets to be conveyed in a single file arrangement.